Re: What kit/engine to buy for fairest price?
It sounds to me like if the cover isn't going on its either the clutch cam not clocked correctly... basically the arm needs to point back... the ball needs to be inside the hole, then the bucking bar goes in after the ball. Also with the bucking bar in properly it should be sticking out about 1/4", if it's in flush with the sprocket or sticking way out, then we need to find out why, it could be something else is in there that shouldn't be, an extra ball could be in there, or the bucking bar was cut too long from the factory... I've seen all the above so rule nothing out...
If this has already all been done and checked, then pics or a video will be very helpful