Wrong xt trans
 

iI bought a trans that was suppose to be an a 89 (wanted it for my 85TT) well it's a 1990 up! (has the nut for the c/s sprocket) also fine splines for the clutch. the drive gears are wider also. fits in the case bearings fine, but they moved the spacing--the gears don't mesh. :oops2: anybody need a post 90 trans--pm me.

Have you checked if there is a difference in the old vs. new geardrum? Suppose by reading you havent changed that yet. Also the shift-forks.
Also keep in mind that a gearbox is really tricky to shift gear in if there is no oil in it. And ofcourse if all the transmission parts are fitted in one open crankcase(for testing gears). In that case be sure to hold the geardrum and gearbox axles in their right positions when testing the gears.
I can also recommend to look for a pdf-manual or parts list to look at, there you can easily see if something is wrong..

I can see by looking on the picture that the gears are not exactly alike the gears in my XT600-2KF, 1987-1990.

Good Luck!

/ Henrik