KLR250 Clutch Issues
Hoping someone can help me with this,
Rebuilt this clutch about 6 times today ripping my hair out now,
1994 KLR250 / KL250D? UK / European.
The pressure plate bottoms out on the pins,
Can put the spring bolts in by hand (with a socket) all the way.
The inner push rod has about 20mm of free play up and down,
The actuator that the cable connects to doesn't do anything, likely just taking up that 20mm free play before bottoming out,
The friction plate stack (without steels) comes to 17mm, all 6 friction and 5 steel plates are in.
All parts are definitely present, checked against online exploded graphics multiple times, and are to my knowledge in the right places.
The clutch pressure plates arrow is lined up with the marking in the clutch basket.
Really lost on what could be causing my issues.
Any help or advice massively appreciated!