Don: 4 teeth were missing from the kick start quadrant. Which part is the gear change quadrant? Also, only one picture is out of focus. The others are just what is inside the cover. Thanks, MikeHi T140Blue, Hope you have a nice vacation & thawed out. 60f, how nice is that. Like my weather...
Back to the bike. Kind of getting ahead of me. Did you measure pressure plate lift?
The adjuster screw for clutch rod hitting access plug in cover is basically normal & well known.. I've seen this many times & my bike did it. I will wear hole in plug over time. The cure is shorten adjuster screw as needed & cut new screwdriver slot. HOWEVER do this after all the other repairs are done. As your 3 ball cam is not adjusted properly as it is hitting main shaft. Often this is due to not having enough cable free play when adjusting rod. Often will hear a click, but not always when cam is over lifted. That's why I wanted you to measure lift first and adjust clutch rod properly. The fulcrum on bar lever is an important part of mix. We'll revisit this later after you get other items corrected.
Regarding stiff shaft, the shaft is supported at each end only. No support in center of engine case. So if screws are backed off & shaft moves freely the o-ring & bushing are ok. So if that's the case it does seem shaft is bent. Depending on where bend is I wonder if you could straighten it? I don't have much experaince on left foot shift, but maybe a crash hitting shift lever might bend the U crank or outer spindle?? I don't know how stiff these parts are & what is most likely to bend.
Does gear change quadrant move the gears freely when you move it with big channel lock pliers? Zig zag wheel at same time to align dogs in trans of course.
Now you can see how the pawls move out as gear change lever is moved & grab a tooth at a time on quadrant. Pretty clever! Does that all seem to move freely?
5 teeth are missing? From exactly which gear? That is unusual. The kicker gear, ratchet gears & ratchet teeth, bushing & the flat coil ratchet spring MUST BE PERFECT!! A slip of the kicker lever will cause sever knee damage.
I've not seen it, but I've heard kicking back can break teeth from ratchet pinion. Kicking back is caused by incorrect timing, lean carb idle circuit, not tickling enough, & very importantly not kicking hard enough. In any order.
Again verify you have 5 speed pawls.
Back to clutch drag, groove wear in basket & hub, wear in spider inside cush hub, can cause problems with drag. Owners get frustrated & try rod adjustments to help. Worn clutch parts never work right. We'll revisit that after you get clutch off.
I found the last set of photos were blurry especially with enlarged. Hard to see the details. Not really needed to repost them, but if possible try to get crisp photos. I know that's often not easy.
In every case get the later shifter springs 57-7051. I'll post photo showing older & new versions. Curved is improved version. Of course these won't cure binding shafts. Just makes good parts shift much better as lever is reliably centered. View attachment 716500 View attachment 716500