transmission not moving freely on rebuild of KZ650

Hi. I am rebuilding a very low mileage KZ 650 engine. When both gear clusters are fitted, there is intermediate snagging when turning the clutch shaft in normal engine direction in nuetral and all gears (this disappears in opposite direction and also when engine is turned upside down ?). When the kickstart shaft and idle gear (which seems in very good condition) is removed there is no problem at all. I have refitted gear clusters and kick start in spare crankcases and same problem, so assume cases are ok, also bearings are fine.
Any advice much appriciated.

Cheers, dave

It sounds kick gear related from what you're saying. Double check the manual or a parts schematic to make sure your kick gear components are installed correctly

daverclasper wrote: ...there is intermediate snagging when turning the clutch shaft in normal engine direction in nuetral and all gears (this disappears in opposite direction and also when engine is turned upside down).

You are turning the clutch shaft in the right direction, right?

Looking at a running 650 engine from the right side (clutch side) the crank, secondary shaft and output shaft will rotate clockwise, the clutch shaft will rotate counter clockwise.

Btw, when turning the clutch shaft, do you have the kick start return spring installed?

If not then make sure that the kick start ratchet is fully disengaged, the stop on the inner ratchet should be resting against the flat part of the stopper plate as in the pic below:

Thanks guys. Think I may have sussed it out. There is a lot of wear on 1st gear pinion bush. I think this may be causing the interferance.
cheers Dave