Clay -

I think you're close. The switch can't go in too deep, but the switch pressure on the rail in combination with a very tight edge somewhere is stopping the rail... it could be the pressure from the switch moving the end of the rail so it doesn't clear the tailhousing pocket - or switch pressure creates a very slight bow in the rail that causes one of the detents to catch on a misaligned edge in the mating bores between the case and the chain cover. It p*ssed me off, though - I do know that. <img src="/forums/images/graemlins/lol.gif" alt="" /> After I drink enough coffee I'll go take it down again and look at the parts carefully in the daylight under a magnifying glass.... maybe then I can see where it's binding. I really don't want to start grinding on the tailcover housing with a new seal already installed, but if I have to, I will.... hopefully I can loosen the chain cover and knock it into better alignment.... we'll see.

Frank