H100S Gearbox/Clutch Problems

[cb1rocket]

(Have posted about this some 2 weeks ago but have decided to get at the bike today to look at the problem)

Basically the problem is that the bike is virtually impossible to change gear while the clutch lever is pressed in. Change gear while the engine is off and do clutchless shift ok. Try changing gear again with clutch in while engine is off and its impossible! Gear lever is not fouling but something to do with the clutch is fouling/pressing inside the engine I believe. Its very rattly noisy and the clutch lever pulses as you pull it in.

Well I got the clutch cover off today to inspect the clutch basket and gear selector assembly and everything looks in order. I even tried turning the gear selector drum by hand and that was ok and smooth.

I'm bit at a loss here, but I must say the plates on the clutch do sit quite far away from the bottom of the basket if that means anything. I have seen other clutches but this one does look a bit odd. Best way putting it is that it seems the shaft that goes through the clutch has come a drift a bit.

Help!

I really don't want to split the cases unnecessary if its something I have overlooked

[spyuggy]

If you bought he bike second hand, someone may have replaced the clutch with the wrong one, when you mentioned the spline, it suggested to me that the clutch drum is too large for the spline to fit smoothly and this would explain gear changes are ok without the clutch, but impossible with it, as the drum is possibly wobbling when you pull the lever in.
(worth checking the manual for size, or borrowing another clutch, just to try it)
Best of luck with it anyway.
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[cb1rocket]

Could be that the transmission bearing has collapsed.....? bits of swaf all over the place at the bottom of crankcase.

Its my brother's bike which he had for a while and put loads of miles on it. Engine runs great, shame about the gearbox problem!