Ok, I did a complete top and bottom end rebuild and broke-in everything properly. Bike starts right up and runs strong! No obvious running issues at all.
The problem is there is a weird "gear" type sound coming from the clutch side. It happens right from idle, with or without the clutch pulled in, and increases with throttle.
Now I have taken apart the clutch cover 3 times and inspected everything. I have replaced the entire clutch basket with a new aftermarket one including new cushions, I have new springs for the kick starter, new idler gear bushing, everything seems installed correct and tight!
At first I thought it was the cushions but after 2 different baskets, it still does the same thing. Replaced all springs, several misc bushings within the clutch cover area and cant figure out where its coming from. It runs fine, but I would like to find out what it is.
Tranny shifts really smooth, and I don't think its installed wrong or anything?
Any advice?
Here is a clip of it running: http://s121.photobucket.com/albums/o215/ba...=MVI_2311-0.flv