i.imgur.com/uTqdHMi.jpeg
  MikeK hope this helps

Thanks posting clutch adjustment instructions everyone! 

I gave MikeK benefit of the doubt that clutch was adjusted correctly...  but sometimes the way a response is worded gets my "spidey sense" tingling and I'm not sure? 

Hopefully the problem will be resolved soon...  and if it is the adjustment, how to do it has definitely been made clear by you guys! 

Thank you for all the guidance and information.
i am going to take the clutch cover off and inspect, measure, test and adjust based on all of this.
Will post here what I find :-)

Good evening… I am sitting on my work stool staring at my empty clutch basket….
I can rotate the inner basket (right term?) by hand. I would say that it is slightly stiff to rotate. But don’t feel that i have to force it; it’s not a struggle or hard work . It doesn’t “freewheel” if i try to spin it. Stops instantly when i stop rotating by hand.
As best can be advised from that description, does that seen right?
Thanks,
Mike

Does outer clutch basket have any in and out freeplay? 

Hi,
Didn’t notice any, but wasn’t looking and all apart now as i wanted to check the washer plates. Which seem ok.
Been messaging my builder who is doubting himself and wonders if he missed out the push rod ball bearing. Had the bike almost on its side, blasted air into it, rattled the actuator pivot and nothing has come out, including the pivot side pushrod.
End of pressure plate push rod seems ok.
Would absence of ball bearing cause my problem?
Any magic way to get the pivot side push rod out… so can be sure that ball is there… or not!
Thanks,
Mike
 

If you put the inner hub back on the shaft with the spacers and washers and with nut tight but without the outer clutch basket do you still have the same stiff rotation of the inner basket?  If not, then there may be an issue with the tall spacer/bushing and/or the washers.  Tall spacer has to be slightly taller than outer clutch basket so that outer clutch basket has a little freeplay...  if not, outer basket gets "pinched" when nut is tightened and clutch won't release properly.  I've seen this a few times. 

Ball usually rolls out easily in my experience...  it could be missing.  It's 3/16 inch.  The thing about that is the clutch arm and "nub" alignment/adjustment.  Pretty much impossible to get that adjusted correctly without the ball and if you somehow did, the clutch would work fine...so please review the adjustment process

Thanks… tried that and inner basket rotates freely. But not sure what it proves. I understand that:
> outter basket will rotate on the spacer unless locked to the inner basket by the clutch.
> if the spacer is worn or the washers are not smooth, there could be friction between inner and outter basket when bolted up causing drag.
> If it is that friction which could be the problem, not sure what bolting up the inner basket only shows.

Just ask as i want to be sure I understand how it all works to help me solve the problem.

Irrespective I have ordered a NOS spacer as I found one relatively cheap and I have a new outter washer plate anyway to fit.

Can’t get a ball to come out! Have ordered a 4mm magnetic tool that will go down the shaft to see if that will pull out the ball, or if it is missing pull out the inner control rod (so i can be sure ball missing).

I have a spare ball too!

Thanks,
Mike


 

I'm not up to speed on this one but i just copied this out of my post#16 "its now down in the second bit" but is only relevant if the hub is pretty much locked solid. If you can turn it by hand it should be ok but ideally should be pretty much free to spin by hand in neutral. But think it was Mark asked about end clearance for the basket & should be able to feel a fraction & only needs running clearance to avoid locking the hub solid. Basket moving on the big basket gear might give a false indication of end play so keep that in mind.

This i copied from #16
I say that because i've seen them lack center end clearance after being dismantled a few time over the years & the nut done up tighter than previous this time, but i'll get back to that if it 'is' the case.

MikeK, you reported that spinning the inner hub felt stiff.  But you couldn't answer the question about the outer basket having a little end play because you had torn it apart.

If the inner basket turns more freely without the outer basket installed, that would seem the indicate the drag is from the outer basket getting "pinched" when nut is tight or there is something wrong that is preventing outer basket from spinning freely on the spacer.