Radduck - sent you a PM.

Thanks for the suggestion Jay. Unfortunately it didn't help. I may have found another engine. We'll see what happens.

I know about spinning the gearbox.

Is this the plug? If so, what should happen when I take it out and what comes out with it? Should the drum spin more freely?

Thanks Jay, I got it figured out. Something is causing the gear selector to bind. It's not moving nearly as freely as it needs to and seems to be getting worse which means a motor / trans teardown. I'm affraid I don't have the tools or the money to pursue this right now so I'm talking with someone r...

Yep. I got that. I'm more concerned about the cable between where it exits the stator and gets to the rubber block. There's not much clearance in there between the flywheel and the cover and there's nothing holding the cable down. If the cable creeps after the cover is put on the flywheel will come ...

Thanks for the pic. I'm trying to figure out how to keep the wire from ending up in the path of the flywheel. It's a trick keeping it tight against the cover.

Does anyone have a picture of the inside of the stator cover with the stator still in it? I need to run the wire from the stator but it's not clear how it stays clear of the flywheel.

Well, I think I figured it out... When I put the bike into first the dog arm is dropping down behind the drum pin and getting stuck... http://i1149.photobucket.com/albums/o600/ahdoman/DogStuck_zps3268917e.jpg After I shift into first it should look like this... http://i1149.photobucket.com/albums/o6...

Already messed with the clutch. Tried it with different tolerances to the retaining ring with no difference. While the clutch pack was out I also messed with finding neutral. It's just as difficult so the clutch isn't the problem. Also bled it. All seems to be well on the clutch side of the bike. :o...

Well, it looks like I'm going to have to take a look at the dog selector. How much oil comes out when I pull the alternator cover? Also, I didn't see a gasket for that cover is there one?

Jay - how do you do the selector dog adjustment?

Clutch M/C was rebuilt about 6 months ago and fluid replaced. The clutch has been working great for the past 6 months. I repacked the the clutch assembly with spare discs and plates I had. Also changed the oil. No metal fragments in the oil so that was encouraging. I haven't had a chance to get the ...

Thanks McTool. Do you know what your clearance is between the outside plate and your retaining ring? I've repacked the clutch with the thicker, one sided plate on the outside but it only leaves me with about 2.5mm of clearance. I was told you wanted closer to 6mm.

Oil was done less than 2k miles ago (changing it now to see if there is any metal in it), clutch bled about 6 months ago. I was looking again at the clutch FAQ on this website and it shows the last friction disc (yellow) as being 3.5 mm and the drawing makes it looks like it is one sided. Is this th...

That may be possible but we were in the local mountains for most of the day and it was rather cold. Also, I've done long rides before in warmer weather without this happening. I'm also running with a vented cover now. I'm starting to think it may be something in the transmission because when its on ...