I don't know how you got the clip and washer on without the selector in place on the drum. 

Something isn't right.  The clip and washer keeps the shaft from sliding in and popping off the drum.  Did you force something to get the clip and washer in place? 

Mark,

The cir clip went back relatively easy once I had access to it........

I pulled off the right side case to check things out and the claw arm is popping off out of place from the shift drum.......  When I place it on the drum while the case is off it shifts just fine.   But it came off when I put it all back together.

Any additional thoughts for me?

Can you take a picture of the clip (shift lever) side?

Think i'll have another cuppa. Wonder if the arm has got bent away with whats been going on but shouldn't really happen. Has someone put a thick washer on the shaft behind the return spring but that's compromise getting circlip & washer on the other end so was just a thought. From where you are with cover off it'd be easy to pull it out & check. Then sit arm on & washer plus circlip the other end & cycle it through the gears with cover off & see if--or why--it climbed off.

Could you have bumped the shaft before circlip & washer were back on.

I'm wondering if clip is under the seal?  (If the seal is installed at all)

OK.....Mark & TR325

The cir-clip was off again  ........    I have anew one on order so when it arrives I will install and push it back and forth to make sure that it is seating in the shaft "grove" properly.

Thank you for the continued advice.....



Worst case, the entire shaft mechanism with dog leg etc is only $36 new from Partzilla 

Make sure you clean the crud out of the groove.... 

Snap rings and e-clips have a sharp edge and a rounded edge...  happens with the manufacturing (stamping) process.  Make sure the sharp edge of the clip is facing out towards you when installing in groove. 

Good advice......  I'll do both for sure.

Things that just shouldn't happen under normal circumstances.