And here is another vid:
https://youtu.be/9C1yHR5EhLw

Hey Go_Hercules. Sorry i have not replied to this post in a while.
in the mean time...
I replaced the throw out (clutch) bearing. That didn't seem to make any difference, sadly.

I managed to make a few videos of the situation, so as to describe the noise:
https://youtu.be/_P3PLe2GUrQ

---Jumping off from the Ace 100 lighting thread..... My Dimmer switch was broken inside. Don't think it was original, but not sure. Now have a new 3 position switch with a side mounted horn button and an open non wired button on top that I assume can be wired as a kill switch. I cut the old switch o...

I deleted my comment here and started a new thread "69 Ace 100 Dimmer Switch"

Thanks. Heh! So the last position on the ignition is kind of like an "accessory" position? So you can run the lights in ON position without the bike running? Flashlight mode? What Ignition switch position do you recommend running the bike on? Mine is the 69 Ace with Ace 90 wiring :-). Not ...

I assume the Ace 90 dimmer switch is 2 position only? along with a horn?

Where is the "emergency" switch? Do you mean 3rd position on the early Ace100 ignition switch? Or is this on the dimmer switch. reason I ask is I'm about to replace a broken dimmer switch on my 69-Ace 100 (ace 90 wiring diagram), but it looks after market with a 3 position switch on the si...

https://youtu.be/ugp52-pEtfc
OK check out at 5 seconds when you can just see the clutch lever move in the foreground, the gear box is farting.
Sorry best analogy I could think of at the moment.
It a puffy gear-y grind like a ratcheting sound

I think the manual refers to the 2 washers as Inner Clutch thrust washer and outer Clutch thrust washer. i remember seeing both and I remember placing the Inner washer against the main bearing. Now the thinner washer must have been stuck to the clutch hub because, in my minds eye, I don't recall not...

Thanks Clarence.
Excessive side play? the spacer ring?
Thrust washer is there, last in line up against the big bearing. Pinion bearing X is facing engine.
bad Sprocket seal makes sense.

Clutch rotation inspection
https://youtu.be/JD8wFJ25b8c

Ed, when I laid the bike flat, the oil went out a vent somewhere when I stood the bike back up, and drained out the other side somewhere. What could have happened? i want to avoid that in future...

Clutch disc vid 2
https://youtu.be/9O8To01vDZ8

Clutch disc video
https://youtu.be/TTAzyj6dUfk

I have to post one url at a time. Sorry.

I know, its a wonky wire job using old original wire. getting new wire soon.

Hey Ed, thats smart! does the oil drain to the other side? does the bike have to be totally flat?

here's a video.
its hot here so don't laugh at my flip flops, heh...
Was trying to keep it lit while giving the clutch a few squeezes (and holding the phone)

https://youtu.be/ugp52-pEtfc

Thanks HJ,
Looks like I'll be draining this oil no less than 2 more times. I better go finish up the sour cream and salsa in the fridge. Need the tubs

Since you have strange noise all the time when you pull in the clutch lever, I have to wonder if the bearings in the "clutch disc" Ed, you may be on to something. that disc was all wobbly. Now I don't know what acceptable amount of 'wobbly" is passable on an old bike but if that litt...

Thanks HJ, Here's a quick reply (well it took some time and I appreciate your very detailed reply) 1. When you say you installed new clutch parts..... I got the Clutch rebuild kit Item# 934000kit for the Mdl 92, 93, 94, and 96 It has 3 black (thinner than stock) steel clutch plates and 4 fiber frict...

Bill. Maybe I need more spacers. The lever moves more than 3/16 for sure. Just trying to imagine why the "graunch" sound would occur through the entire pull of the clutch distance. Just sounds "bad". (original problem). Maybe it is a cable adjustment at the case, but to be honest...

The clutch is making noise throughout the entire pull of the clutch. The same as before. yes.

Happy 4th y'all. .........Light Fuse - Get Away. Pardon me for taking this back to TDC. Top Dead Center (or Total Doofus Cranium) Insert your TDC here.......... Installed new clutch pack parts, newer type, along with new pinion bushing. The clutch is acting the same, with just a tad of clutch pull, ...

I can imagine with the new design you get an increase in oil flow.
Is this the "blueprint' ?
http://www.strictlyhodaka.com/Articles.asp?ID=252#link3

Hey HydraulicJack, I posted too soon, must have been typing when your reply can in. Thanks for your reply. Will update the set. I have a question, (and I may answer it myself when I start to put it all back together) How do you get the clutch pack spacing correct, relative to the screws and screw tu...

New specs after checking this am:
Spring height: .73 to .75 (using manual mic and set of old eyes!)

Friction disks: not perfectly flat but not sure if this is typical. #2 has a burr on inner teeth. Problem? Thickness: .073.

Clutch Plates: all flat except for middle one. See picture.

Got the clutch out and just going through parts. Clutch pinion bushing seems sticky. Good call on that. See the clutch pack below. What does this wear pattern tell you? Time for an upgrade- maybe to the newer type clutch disk set? There seems to be 2 part numbers at least that will work for this yea...

As you can see my pipe isn't going to win any beauty contests. So, if one turns up for a 69, let me know