Clutch woes

[KXTodd]

I have replaced on my 98 KX250 the following:
Basket-new hinson
Clutch hub-stock
Pressure plate-stock
Steels and fibers-stock
Cable-motion pro
I did soak the fibers for a couple days first, have taken it apart 3 times and put it back together, it IS right!
The problem is I cannot get the clutch to disengage, like the plates are sticking?? I warm it up ride around a little bit, try adjusting the cable back and forth(put the new cable on as a last resort) and it doesn't seem to change. It does seem to have the right amount of pull, the pressure plate is coming out a decent distance and I can easily pull the plates apart when looking at it with the cover off. I have done a clutch before and it was simple. Does it just need to be broken-in or do I need to ride it a little harder to get the plates to seperate or what? Going crazy with this bike!

 

[marcusgunby]

You havnt lost the large washer that sits between the baskets?

 

[KXTodd]

Nope.

 

[marcusgunby]

can you measure the stack height of the all the plates and compare it to a known number(maybe its in the manual?)

 

also check to see if all the plates are completely flat.

 

[KXTodd]

I didn't find anything in the manual aboutt the stack height? Springs check out good too. I'm going to try to take it out tomm. and ride in a more open area and see if it loosens up? If not I'll take it apart agin and check to make sure they're flat. Anything else?

 

[marcusgunby]

Is there a ball that sits at the end of the push rod in the 250-these often drop out when doing work on them.

 

[marcusgunby]

heres a link to a exploded diagram of the clutch-check you havnt dropped any washers out-

http://www.buykawasaki.com/Default.asp?Site=Accessoryâ^«CatalogID=1&CatalogTypeID=4&ProductTypeID=10

maybe  washer no 920288

 

[KXTodd]

Check, check and triple check :) I had checked out that site too just to be sure it wasn't diff. from my manual. I have that washer but I did want to check the thickness of it and forgot, next time I take it apart. Thanks for the legwork!