Aluminum particles all over the place 2018 300

[5valve]

Washed gearbox, poured 75W90 leftover gear oil to further flush, works great, silent, but maybe not clutch friendly if abused.
Its not thick oil, corresponds to 10w 40, good for final cleanup.

[5valve]

Went for a ride, locked again. Freed afterwards. New particles, some bigger also.
Halved the engine...nothing special inside. Last pic..spring and ball were inside dropped oil. I do have wet mod starter mechanism, but never saw such spring in gg engine.

[(F5)]

If it was a roadbike I'd say neutral indication at end of shift drum.

Neither look gracked up enough to lock an engine.

Lay out gearbox and check against diagram for missing washers.

Check all clutch washers. Check everything close up for sign of mechanical violence.

[SS109]

That part in the red circle I don't remember. Is that from something grinding it? Also, you can tell the crankshaft side clearance is off by virtue of the shiny metal on the case where the red arrow is. Of course, it's been a long time since I've been in the bottom of a Gasser so maybe I'm just not remembering those two details.

I agree, check all washers and thrust bearings for proper thickness and placement. Something definitely isn't right.

[Zman]

I fully agree with SS109!

[5valve]

For me, spring and ball is some kind of check valve, but nothing like that on any 2t.

Encircled part will check the cutout, but it is most probably made for the gear.

You're right on the bottom end side play, but this is gearbox secondary shaft area. Will go through some old pics to check for polish being factory or "aftermarket"

[(F5)]

I'd assumed the cleaned up are was std. Just looked at some pictures from my 07 in July but have gears in the way.

But SS109s 2nd circled picture is clearly where your swarf is coming from. That ain't right. That gear is walking where it shouldn't be able. Check the gear and meshing gear edge well. I think you may have got lucky that it just ground hard against the case rather than latching 2 gears at once where would have gone kaboom and put you on your side if at speed.

[5valve]

Damn if that was "the case".

I did find a pic from 1st dissassembly year ago...current one is 3rd.

Encircled cutout corresponds to cast roundness to fit the gear.

[SS109]

Cool. So, what is grinding in there? I still would double check that location as best I can tell from the pics that cut out looked smoother in the before pic.

[MxPhlipper]

Damn. Completely unrelated I'm sure, but spring/ball bearing reminds me of kick starter rebuilds, way too many times, on my Maico's/XR/XL.

Also, the needle bearing where the red circle is reminds me of the ONLY bearing in bottom end of my 82 Maico 490 I couldn't replace. Worked great in Fort Hood TX for 20 min then nuked itself. Ouch!!!!