'94 Ultra, rebuilt the clutch basket. Reinstalled the clutch basket, adjusted the clutch, then adjusted the clutch lever. Pulled the clutch lever in and the whole clutch basket and mainshaft moved out a total of about 1/2". What gives?

 

There's no easy answer to that. If it was all fine before you stripped it, everything should go back fine on rebuilding it. Unfortunately you need to dismantle it and investigate. For future reference we have a dedicated Evo section, where you will meet up with more owners, who can help with technical challenges like this.

 

5 speed transmissions are used on Evos, Shovels and Twin Cams...

This is the transmission forum, this is where this question belongs...

I suggest removing the cover from the right side of the transmission and taking a look at the ball bearing at the right end of the mainshaft.

 

Dan, the unfortunate truth is that while your statement is true, very few HDF members call by here, as the post count on threads shows. There is more expertise to hand in the dedicated forums.

 

I'll second this possible diagnoses.