At long last, a promising solution
Not a general life solution, but this one is the next best thing.
If you go back a couple pages you’ll find some pictures of the shift dogs. They are very chewed on, note the parts that are not broken off, but ground off. I believe this is the problem I have been looking for.
I believe that the shift drum is not holding the dogs in the right spot and that is allowing the gears to slide back and forth on the engagement shaft. When the gears hit the engagement teeth, they get kicked across the shaft and into the shift dogs, and take a piece out of it.
I believe this is the case because I have pulled flakes out of the oil pan that look exactly the same as the flakes from the old shift dogs. I know this, because in my hunt for the noise I was convinced was the timing chain, I happened to drop a washer down into the belly pan and hand to fish it out with a magnet, which came back with metal flakes.
I could really use some help with this. If anyone has experiance with this.
I feel like a reasonable solution, would be to get a thin washer and shim the shift drum in order to move the shift dogs over and hold the gears in the right place.
Smoke?
Looks like one of the rings has gone bad. Seeing as this engine has had a hard life, I think that the rings ought to be redone before a track day anyway. I don’t particularly want to redo everything inside the case particularly, but what needs done, needs to be done.
Here’s what I know, There was a little smoke when I hit the gas hard. The engine is making a tapping sound.
This comes after a brief spat with the tilt sensor, which was not allowing the fuel pump to run for some reason. (I did drop the sensor on it’s side and I think the mechanism stuck there. Fixed now. With a hammer)
