The lockout was replaced last summer due to it being messed up when the basket broke. I double checked it and the arms move freely. Pancake was adjusted properly. actuator arm lined up to arrow when just touching pancake to pressure plate. I always run a little slack on the clutch lever.
I did notice some wear on the washers on both sides of the spacer, also my basket bushing had some wear lines. I'm wondering if I distorted it a little when pressing into the new gear.
Anyways, New washers, Spacer, Bushing & kicker gear, Chariot basket, Center Hub, pressure plate. Ended up going with Barnett 401-90-047015 steels and Vesrah vp-2041 frictions (equivalent to 4H7-16321-02-00)
I'll report back in a few months or if/when something breaks again. Thanks for the help.