That transmission will not shift partially assembled. Neutral is located on the shift drum by the spring tension roller. Did you check too make sure the forks are straight? You can put the forks back to back on the same shaft to check. Good luck.
This is an example. The picture on the left is a good `03 shaft. The broken one in the middle and the one on the right are not compatible as the pawl will not interchange. All three are different.
You are wasting your time unless it is for an extended period. I rode a TY175 around this weekend ( After my Gasser broke). It just came out of a 25 year storage in a nice dry cool barn. The Dunlop 2 plies were made April of 1985. They are a little hard, no cracks and still have the tits on the tire.
Glenn, I had the 350 model before I ever thought of vintage. It was the best twinshock I ever had. The Montesa`s handled better than any other brand. Parts are crazy hard. Any Ty is a piece of crap. (But there sure is a lot of parts for that crap) Let me re-phrase that. The older Yamahas were crap. I loved the mono! By the way I just spent the last two days running around on a TY175 after my gasser puked all the tranny fluid after the first loop Saturday.
In trials you have too move. The only time I ever needed a chest protector was Desert racing. When you are running down an arroyo at 70 plus, those rocks can hurt. At 5 mph you should be able to take care of yourself. Believe me, that should be the least of your worry in trials.
What you did not include is a picture of the kick start shaft and pawl gear. This was very common on 02-04 models. There is a new shaft and gear upgrade that is not cheap. Also check the blind bearing in the case. You can get to it from behind the carb more or less.
Actually the best tool I have is my motorcycle air lift work bench.( I`ve had it for thirty years) I can easily put four bikes on the skid plate and have room to change the tires on all four bikes!
Are you sure the clutch is not just slipping. I remember your old posts and video. The clutch will just barely slip and will cause the problems you are having.
Bike Stand
Aluminum box for oil or parts.
3 feet of clear hose, that is all you ever need to bleed hydraulics.
WD-40 I buy it by the gallon.
Firm believer in Maxima lubricants.
Box of spare parts. I hate waiting for spares.
