well i recently blew out the clutch on my 03 baja ds and i replaced it with factory plates and got tvi springs but when i went to put the cover back on everything went smooth and i tightened everything up, started it up and went to use the clutch but it would only pull just a tiny bit and if u pulled any harder it was almost like the splines on that shaft were skipping on the other shaft coming out of the clutch hub, i disassembled it to find nothing wrong then reassembled it and it did the same thing, i dont know what to do, some please help me i hate havign to take things to the dealer, they charge out the ***.....

 

Make sure you have the clutch spline shaft lined up correctly with the cover when you put it on. That shaft turns and if it isn't lined up you could have some problems. That's all I can think of right now. Hope this helps.

 

what pushin said, make sure the two shaft gears (or what ever you call them) line up, i had that problem too when i upgraded my clutch springs, and that was the problem

 

I just put my clutch back together last night. It took me a few tries to get it aligned but I got it and it works fine. My concern with your problem is that my cover would not go on all the way when it wasn’t aligned with the shaft. I am wondering if you may have packed the clutch incorrectly. The last friction plate is installed in the short slots of the clutch basket.

This is the only other thing I can think of other than the shaft alignment.

Let us know what you find.

 

I had some trouble with mine, and it was that one of the teeth had broken off of the rack actuator, as bomb calls it. The shaft looked fine, but the rack that goes into the clutch had a broken tooth.

I replaced both and no problems now.

I would double check them.

Bat