Smithabusa Gear Indicator installation questions & Clutch problem ALL FIXED

[Volvi]

Thx Shane. Rod and I today worked on installing this unit. Whilst the GI worked I cant say the same for the clutch. After all was done Huston we have a problem. I'll put it to you as I just did to smithabusa in email, see if you can work it out:

Troubleshoot:

Ok lets run this by you, seeing youve probably taken clutch basket in and out more then anyone else I know.

Installed unit today with a friend. Found bit tricky and fiddly on reassembling clutch basket. Kept all clutch ring/disks in order, last one slotting into shallow insert whilst others in deeper side inserts.

All assembled. Warmed bike up first allowing oil into basket. Pulled clutch lever in.........click, click. clickty click kinda noise from clutch basket. 1st gear in GI showing position OK. Slowly release clutch no pull, no go. engine not engaging transmission, same if went up to 2nd gear. Every time clutch lever pulled in same noise and bike wont move forward at all.

Were totally baffled as to why. Were pretty sure we put in every bit in its right place. The clutch plates perhaps moved around in circle as was very fiddly getting them in, but made sure last one was offset to shallower groove.

Any ideas what went wrong, where we might have done something wrong? The noise isnt a mettalic sound almost like woody clicking.

Mine is a '99 model and the Back Torque Limiter welded up as the BTL mod.

Any ideas?