I'm reinstalling the engine after a top end rebuild on my 03 Predator 500. Prior to rebuild the clutch worked fine. I did pull the clutch off to make sure I had the lower timing mark in alignment. Everything was marked and reassembled as it was. Now the clutch lever does not return. With the cable off the engine the lever does move freely but not a whole lot of tension. The engine is still dry and has not been started yet. Should the clutch have more tension now or am I missing something?
Thanks.

 

Should be about 3/16 to 1/4" free play at the lever,but you should have tension when you pull and should release back. Retrace your steps,check the case lever spring along with the internal clutch parts,clutch springs,rod and pusher. Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse