significant clutch drag even after clutch overhaul

[Tiger800XRX]

Frustration!! The bike had been laid up over winter so I periodically ran the engine checking clutch and gear operation. Clutch drag got progressively worse, but this was overcome by rocking the bike in gear, however eventually this didnt work. I use 10W/40 oil!

Stripped the clutch, everything in tolerance, including flatness of plates, dressed the clutch hub and cage, Thought the friction plates may have glazed, so renewed them and the steel plates. The clutch hub rotates freely independent of the Clutch cage. With the engine off, I can select all gears no problem. When I try to select a gear with engine on, the gears clash and engine stalls.

When I have the bike on paddock stand, neutral is fine, but when the bike is not running but in gear, and the clutch lever pulled in, or even manually operating the clutch operating arm it takes some effort to rotate the rear wheel.

I am at a loss, but sometimes you get foggy brain when thinking about a problem over and over, My friends have drawn a blank, but I hope someone here will say...I've had that problem, and suggest possible solutions!!
Thanks for a great site

[HolerTogni]

Hi Tiger800XRX!

Never had - or even have heard of - the problem you described.

However, I might as well have a guess on the reason, right?

My guess is that something of the clutch internals referring to the operation the clutch might be assembled in a wrong way or order.
Did you check the correct operation when assembled but without the clutch cover?

No specific ideas, I'm sorry, but this is what came into my mind spontaneously.

"Successful tinkering!" - greets from Munich!

PS:
Maybe you should post in your other three (identical, I guess) topics that all* the answers should be posted in one thread.
I don't know whether dicky can delete or close the unnecessary ones.
* to be honest, not much answers to be awaited these days ...

[dicky]

Does it still stick when fully warmed up?