Smooth gear change at last!

[b1k3rdude]

I think the best way to check the chain is not too tight is to make the adjustment then get a couple of mates to sit on the bike.

that was the thing, when I did the 35-40mm I sat on the bike while the tightest spot was checked etc. Anyway, gonna keep an eye out for a replacement clutch cover and then do the clutch-hole mod.