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Not good

Hmm another observation
Did a dry shifting without gears and even though i held the forks up, they seem to get stuck on the drum preventing the drum to spin freely into each gear...

Here

Lower casing

Yeah so if i only have the drum in and turn that it turns fine and sits everyt time in the plunger? That goes from undernearh the engine case up in the drum

Well not sure if it shifted fine, it shifted but needed force.
The manglede piece i believe is a shim from the tacho drive gear, but your right,gonna check that. But iam almost 110 procent sure the forks are in correctly but I will check again Thanks

Only pictures i got now. I have several forks but these for one

Okay, gears are not working as they should
No were near shifting consistent just crap.
I have narrowed it down to believe Its the forks and or the axles they run on and the pins that run on the drum grooves.
Seems like those pins would benefit from having springs behind Them so they follow the grove 100 procent, Its as if they have a tendency to get stuck... No real damage to the drum either..

Allright. Been at it all day not sure what to think. I have put transmission in and shifted through the gears, but how easy should it be, being and old bike? I am shifting just lower engine case with Nothing but gears in the casing.

Ah okay. Damn... Hmm.. Not sure what i can be then but Will try tomorrow with a different drum and dry run some shifting before doing anything Else

I actually suspect that maybe the shift drum i put in the engine is a Rd350 ac model? When dinding pictures on ebay they look similar with the size of holes

Ahhh yes i believe your right. There is a washer behind the circlip. Awsome will find replacement tomorrow

Thats a good tip, Thanks :)

So, no original drain plug.
Took the engine apart. Wierd - there was this piece of Bent metal sitting behind the oil cover?
Besides that everything looked fine No metal shawings or Any thing.

I removed the shift drum and compared it to Extra spare parts rd400.
Is it the right drum? They are pretty different...
The one i removed from the rebuild engine is the one on the left!

Seriously.. Iam not in the mood for Taking everything apart and engine cases to change the gear drum, but it seems like thats to fault. It wont shift, unless i give it a little help on the drum when the cover is off