My buddy has an '07 300ex that the clutch wasn't engaging until you let the lever almost all the way out. (was like this when purchased used) We put new clutch plates and springs in and it barely helped.
It now has about twice as much clutch to work with than before but it is by no means normal.

I have an '08 z400 and the clutch begins to engage while the lever is just starting to be let out. All other sport quads I rode have been that way...

I can not figure out what the problem may be, any suggestions?

 

Sounds like the spring that goes behind the plunger is missing.

 

could you possibly show me on a pic or diagram? We replaced the 4 springs that are shown in the clutch assembly diagram as #8. (It only shows one, but there are 4, one for each bolt)

http://www.bikebandit.com/houseofmot...15681sch419094

 

Ok, sorry, the spring is on the clutch lever shown in the right crankcase cover schematic. What I'm thinking, in your schematic, is do you have all the parts #7, 9, 17, 19, & 20?

 

May seem like a dumb question... but have you tried changing the adjustment? it might help a little...

 

Yeah I think they were all there, but it does seem as if there were an additional washer or something in there the clutch would engage sooner, my fear is that it would then, in turn, never fully disengage.

Never a dumb question...I was honestly hoping for it to be something dumb that I overlooked! (but yeah, we tried that)