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Join Date: Jul 2006
Location: Kennett Square, PA
Charlie, try a couple of things: first, make sure you've got the switch connected to the LH controls in the right direction. Sounds dumb, I know, but it's hard to see the tab in there - and it may be possible that you've flipped it 180 degrees (on Orleans, some of the connector tabs were missing altogether, leaving me to guess in some instances). Also, I don't know what the "default" is on that particular switch, but unplug it - see if that makes a difference.
Finally, in your rebuilding, did you happen to pull the rear wheel to lube the splines? If so, could you spin it with the bike in neutral after you'd put it all back together. If you're not certain whether you did or not, try it tonight - just pop her up there on the centerstand, put the bike in neutral, and spin. It's possible that you've got two different things going on (clutch switch issue; misaligned splines with the trans issue).