Looking again, I've never seen a sliding cam like in pic #3 something looks strange about all that. May be some new fangled eliminator contraption. On the edge of my chair waiting on further destruction of this assembly.

 

I thought about that shaft extension today at work, but today I was real busy but like normal T150vej beat me to it!!

 

OK, got it apart. Old skool:









The front sprocket is somewhere around a quarter inch too far in.

Some thickness numbers:
Spacer behind the rotor: 0.100"
Rotor: 0.175
Spacer: 0.250
Extension shoulder: 0.375

Ideas?

 

I seen that there is no spacer between your rotor and shaft extension, sometimes you need one sometimes you don't, but would help by

about 1/8"

 

Them boys out in West Texas used to carry 24" Ridged p/w's on their key chains. I knew you didn't have enough boot to get it off with a 12...

All the front stuff looks absolutely correct except the super thick spacer, but no biggie there. Only thing about going thicker on it would be the nut length might not make the reach, but that would be the cheapest way out if it will... and assuming the primary has an extra 1/4" clearance in the front end.

Unless that's a post '06 twinkie clutch, I'm totally out of ideas.

Mike, look again at pic 4, the ring on the far right is the spacer that was between the rotor / extension...

 

The inside of that rotor looks like its been rubbing against something pretty bad?? on this bike or previous bike?

 

I thought that was the one under the rotor in pic 3??

 

Hard to tell in the pics, but when I check primary chain alignment, I'll measure and also check if the sprocket teeth are running center in the chain, in this pic it almost looks like the compensator teeth are running to the outside of the chain meaning that the compensator is out far enough? I wonder what the inner primary cover is?

 

This pic the rotor looks like its running awful close to the stator?

 

Good eye Mike.

I'd be tempted to put the .250 behind the rotor and space /shim between the extension and rotor. Check nut engagement and outer cover clearance

If I know Hess, he'll figure out something besides changing the clutch assembly