yz 450 Clutch problem after rebuild

Ok not to go into a long story but I bought this 2003 YZ 450 and it needed a rebuild. Replaced rings, cylinder, adjusted valves, new gaskets.

The bike runs and I get a little white smoke coming out of the exhaust, which I figure is normal with the new rings not seated yet.

But my problem is the clutch wont disengage. I grab a hold of the clutch lever and go to first and the bike clunks and dies. The clutch cable isnt stretched and looks like its pulling on the arm that connected to the disengaging the push lever.

I followed the book to the T when reassembling everything and torqueing to spec. Any ideas on why this is happening? MAybe I should go back into it and see if I missed something. Should I replace the springs on the clutch bolts?

Any help would very appreciated. Thanks

If you replaced the same clutch and cable as before, either something is not adjusted correctly or something is missing. The springs would cause clutch slip if they had gone soft, not cause it not to disengage.

My bet would be that you forgot the ball bearing at the end of the push rod. How far round does the arm push round by hand before you feel any resistance? Is there the normal resistance in the clutch lever when you pull it?

The only other thing that would stop the clutch disengaging properly is a notched basket, but you should have noticed that before the rebuild.

Ok so I went into the clutch this weekend. I verified that the ball bearing is inside the push rod. The push rod looks like it pushes maybe a half inch when I pull on the clutch cable. So it looks like everything is working ok inside. I soaked the clutches in oil and put it back together.

Im still having the same issue. The clutch doesnt seem to be dissengaging. I torqued the bolts down to spec. I used a inch pounds torque wrench I bought from harbor freight. Maybe the torque specs arent right? I know harbor freight doesnt have the most quality tools but I figure it'd be some what close.

Any ideas? Please any input would be great.

Oh and I have not replaced the clutches. Should I replace them? I bought the bike with a frozen engine so I dont know what was wrong with it before I bought it. I assumed the clutches were fine because is had a seized crank shaft.

Oh and I have not replaced the clutches. Should I replace them? I bought the bike with a frozen engine so I dont know what was wrong with it before I bought it. I assumed the clutches were fine because is had a seized crank shaft.

Are you sure you have the right number of plates in there? Try adding 1 more plate. Old trick in xr is add 1 steel at the inside...

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