Well, while draining the oil from the tranny case, a handful of ball bearings dropped out the bottom. Turns out the main input bearing had disintegrated (hence my 2nd gear woes and the locking up of the gears). Found a new bearing after an exhaustive search, cleaned the tranny up, replaced the clutch and reinstalled the tranny. It all went together fine, but now I have way too much free pedal travel. I originally reconnected the fork to the pull rod where it had been with the old clutch (which worked fine), and I practically had to floor the clutch pedal before the throwout bearing would make contact. So I started readjusting the length of that linkage. Now the fork is set at the very end of the rod (closest to the rear) so I can't adjust it back any further, yet I still have 2-3 inches of travel before contact is made.
All I can think of is that the shifter fork isn't seated properly on the ball and maybe there's too much play in the mechanism. Gonna try working the fork onto the ball a little better and see what happens.
Anyone have any other thoughts?
