I have searched endlessly and it seems no one has run into the same problems I am having.
I have purchased these parts:
5JG-16321-00-00 PLATE, FRICTION
5JG-16383-00-00 SPRING, CLUTCH BOSS
5JG-16384-00-00 PLATE, SEAT
93511-32027-00 BEARING, BALL (PUSH ROD ASSY.)
5BE-16356-00-00 ROD, PUSH 1
5JG-16357-10-00 ROD, PUSH 2
5JG-15453-00-00 GASKET, CLUTCH COVER
Here is my problem.
I removed all of the friction plates in order. Layed them out so they had no chance of getting out of order.
I removed the innermost friction plate.
I then installed the plate seat, then the clutch boss, then the new friction plate.
I then put the plates all back in (making sure the innermost plate was removed).
Here is the fun part.
I noticed that the clutch assembly as a whole lines up almost flush with the clutch basket. I assume that is why the new push rods and ball bearing were needed. No problem.........
When I install the new push rods and ball bearing and tighten down all the nuts, the pressure plate sits about let's say 1/4 inch above the friction plate. Needless to say this won't work.
I have also read that the new push rods and ball bearing aren't needed. So I have tried this combination as well.
The problem with this is that in this configuration when I engage the clutch it moves the assembly as a whole, meaning that the pressure plate brings all of the other friction plates outwards with it.
I have tried every clutch cable combination and even unhooked it from the arm. The push lever component just doesn't have the swing needed to push the pressure plate out any farther.
Upon inspecting the New push rods 1 & 2 I can really see no difference so I tried the above with the stock 2 push rods with and without the ball bearing and I get the same result.
I honestly can't think of what I am missing here.
The bike is a year 2000
To answer some questions, yes I have inspected the clutch plates and friction plates for wear and warpage. The clutch basket and hub are not damaged in any way.
Can anyone shed some insight into this?