Yeah Bryan, it was one of those jobs where one problem threw up another.
I believe that the alternator spinning it's self off while she was riding was the catalyst then I lapped too much off the shaft and inside the alternator rotor.
Didn't help that I fcuked up the cam timing 3 times.
I'm gonna grab as much GSX400 stuff from the wrecker before he packs up the shop for good.
I can tell you it is such a bloody relief to have the 400 all back together, Jaffa came home from work today, saw her bike in the driveway, turned the key..hit the starter and it fired right up..no choke no hesitation....boy was she smiling big time.