When I let out the clutch in first gear there is a terrible grinding noise[it sounds internal]
It is a loud noise and sounds like metal to metal
The clutch lever has approx 3 to 4mm free play at the bracket end
It only happens when the engine is cold and only in first gear
The gear changes are smooth and accurate
The oil and filter are new [good oil and the correct amount]
The bike is less than two years old, immaculate condiition and only 7000klms
The chain is adjusted and lubed and there is nothing catching under the bike or behind the front sprocket cover/side stand
It is possible that the first gear shift fork in the transmission is bent causing the 'dog-clutch' between two gears to just barely mesh. With engine off, push the shift into first and clutch lever released. Rock the bike back and forth to see if the gearing seems to be jumping in and out. There may be a problem with the shift lever shaft mechanism not allowing a complete shift into first gear. Hope this helps!
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