I replaced my clutch this past weekend. I have no idea what I have done wrong. The clutch pull is so stiff that I have partially stripped the teeth off of the rod that goes down into the case. I have replaced many clutches over the years, but this has me stumped. Everything is lining up correct and I have the correct number of plates installed, while using the cushion spring in the correct location. I have tore the engine down numerous times and reinstalled the stock clutch with no problems. When I rode it the clutch worked a bit, but not enough too pull the clutch in and stop without the engine stalling. Has anyone had this problem?
Gary

 

Gary,
I had the same problem with my old LT250R. I found two problems; one, the rod that goes down in the case that you speak of was not lining up for me, and so the clutch pull had too much slack in it and would not pull far enough to engage/disengage. The other problem was that my basket was completely shot. Did you replace the cable too? How did you route it? What kind of lever do you have? Was it an aftermarket clutch, GYTR clutch, stocker, what?

My solutions were to find the right lineup for the rod actuator, and to machine the basket to smooth out the burrs and scarring. It worked fine right up until I sold it.

 

Thanks for the reply bro! I will take another look at it this evening.
Gary