mine with a 180 and a 530 chain. their was 2mm from the frame to the chain and about the same on the tyre side. never had any contact with the frame as no paint was scratched off
wrap some masking tape round the stator 2 times or so then fit the cover, turn the engine over by hand a few times and pull the cover off for a look see.
has you clutch cable got an adjuster half way down its length ? make sure the cable is all the way in ALL the adjusters, one at the clutch lever, one half way down the cable and one on the top of the crankcase.
not really understanding your problem !!! the clutch shaft in the cover stays in the cover when you fit it, the release barrel with the teeth just slides in and meshes with the shaft if its lined up. have you any pic's of your bike/clutch ?
you do with any paint but more so with the 2K stuff, it is very strong !!!! I use a normal face mask when using it, probably not good enough but better than nowt
I think the numbers he's quoted have no connection to the symptoms !!!! but he did mention a hose was missing which is why it won't run on ON & RES. me thinks he's made a mistake