After running 6 heat cycles on it I rode it for a few hundred yards up and down the street.
It shifted fine through 4th gear with no issues.
On Friday I ran it for 20 minutes trying to get some starting heat numbers.
After the test I had to take it for a quick ride.
I pulled the clutch in and clicked it into first.
I gave it some throttle and let the clutch out.
It took off just fine.
Pulled in the clutch and up shifted into second and GGGGrrrrrrrtttt, GGGGrrrrrtttt... the gears were grinding.
But the bike went into second when I let off on the gas.
I thought I blew a shift, although I didn't see how that was possible as I wasn't getting on it.
Then I tried to shift into 3rd and GGGGrrrrrrrtttt, GGGGrrrrrtttt...the gears were grinding again..
I let off on the gas and it was in 3rd.
So I rode it back to the shop and parked it
Today I pulled the clutch cover, clutch basket, ect so I could get a better look at the shift mechanism.
All the springs are there and in place.
I pulled the shift shaft out and inspected the pal, springs, everything that I can see that would be a problem.
Then I compared it to another shift shaft asy I have and it looks and functions exactly the same.
I spend about 30 minutes reading the Clymer but didn't see anything out of place.
Here is a pic with the shaft removed.
The shaft that came out of the bike is on the right.
Another view..
Finally found the problem....
I have to say that I feel like a real dummy...
Guess where the hang up and grinding was coming from....
From the first time I rode the bike to the second time I changed the front sprocket to a 15T from a 14T.
My Dad was no mechanic but he always said, if you changed something and now there is a problem, go back and look at what you changed..
I had completely forgot that I changed the sprocket
Oh well, at least I can laugh at myself and perhaps someone will learn a valuable lesson.
Kinda feel like this...
http://www.mediacollege.com/downloads/sound-effects/movie/napoleon-dynamite/napoleon_freakingidiot.wav