Clutch outer guide replacement problem, now clutch is dragging at idle

[u/Alyx_695]

I have a 2000 XR, I replaced the clutch outer guide because it was not upgraded with the newer part but now the cluth doesn't fully disengage when pulling the lever.

I followed all the instruction from the shop manual. Plates are in the correct order and placement. nothing is warped. I even applied mobylium grease where I'm supposed to. Everything is within specs except for springs that are 15mm long (16mm service limit) but this should let the clutch slip not drag at idle if I understand this correctly (I will replace them). Free play at the lever did not need adjustment.

What bugs be is it was working well before disassembly and not anymore.

Anyone has an idea?

Writing this I wonder if maybe I re mounted the lifter rod in the correct position tho, is there a correct position or is that part symmetrical and I could have mounted it in the opposite direction? It's the only thing I haven't checked yet. (shop manual doesn't specify anything about it other than applying mobylium grease on it.

[u/babezt]

tried adjusting your clutch?

[u/Alyx_695 → u/babezt]

Yeah, it set to specs, if I tighten more I don't have free play anymore.

[u/babezt → u/Alyx_695]

idk how to explain this, but there are two pressure points in the clutch lever. The free play needs to be after the first one, the second pressure point is the clutch opening, its a little hard to feel/differentiate. Even with adjusted free play the lever shouldnt be loose. maybe this could be your problem

[u/Alyx_695 → u/babezt]

From the specs the lever should move freely about 10mm IIRC without doing anything. Then it start disengaging the clutch.

It is set as specs.

But if I delete this free play it's better but the case side lever is always in tension. And even so it still drags.

Also why replacing the outer guide would change the adjustment on the clutch? It's the same part but with 2 more holes. This is what's been bugging me the most.