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I assume that you did install the push rod cup that sits in the center of the clutch assembly? I don't remember the correct name, but if it's not in there the push rod will go all the way to the crank shaft.
I use a ball bearing that is close to the diameter of the clutch push rod. Wanted it to fit in the bore with a good fit and stay centered on the rod.
Tom,Yes I did put the spring plate cap in the correct place.
Why not do the best of both worlds? Turn down or cut a 4X6mm cylinder.
This does raise another question regarding the additional compression of the clutch springs due to the extra thickness. Does this affect the clutch action and/or the clutch lever pull (how hard it is to pull the clutch lever)?
I was going to suggest that you might have installed the friction plates upside down. That can be done and causes problems. Then I read your final fix above. I want to thank you for reporting back and describing your resolution details and action. So many times people come to this forum for advice. They lay out symptoms and receive advice. Then they go away and we never hear back and never know which item of advice actually solved the problem. Kudos to you for reporting back. BTW, did it all work out with stock parts or did you still need to insert a ball bearing? I wasn't clear on that.Patrick HayesFremont CA