Let it sit overnight or bleed the system to relieve the pressure more quickly. You probably pulled the lever while the clutch was apart.

 

how flogged out are the tabs on the drive plates ? if they're well worn and you didn't put them in exactly the same order and orientation they can catch on the basket. I had this happen when i found my basket completely worn. the basket gets notched and the tabs look hammered over on the ends ( completely worn ) . Check your tolerances from the maintenance manual. Also when you had the plates out did you pull out the clutch push rod and make sure it isn't bent ? along with doing a bleed. If you have ad the slave cylinder off, some brands ( after market ) require a small spacer to be installed ( oeberon for example ) if you didn't put this in you clutch will not disengage the plates, make sure its greased as well...it is also not uncommon for this shaft to snap in teh middle and act like a end to end wedge somewhere in the casing if it hasn't been maintained properly. .... see how you go checking those few things. I have a 996 so its the same things to check.

If you have alloy basket make sure you have alloy plates... people make the mistake of using steel plates on alloy baskets and it doesn't end well either... just a few things to consider.

Cheers

 

thanks for the info!! I did reinstall the plates back in the same order and gave it a good bleed but still no luck when I start it and put it in Gear it doesn't engage the bike goes nowhere..

 

Oh.... have you checked all the drive plates and friction plates thickness is in spec.. also that the springs are the correct size (length) also there will be one drive plate that is slightly concaved, you will need your feeler gauges to work out as its hard to see by eye and make sure its inserted the correct way around. you got a photo of the basket with them all installed,, or a video to show the clutch action at the basket when you pull the clutch in and out.... this is a pretty simple part to see if something is a miss on... assume you have a workshop manual on hand as well ? if your basket is spinning nd your allegedly in gear... perhaps your Gbox is the next point of interest ;-) maybe even teeth on the drive gears behind engine side cover ? drastic, but remotely possible...without seeing or hearing .. its just guess work

 

This. Especially if you didn't ride it before you tore it down - you have no idea how worn it was to begin with. Assuming you bled it well and got all the plates back in the right order and orientation (didn't flip a concave plate as Madryan suggests) then the next 3 culprits are:

1) incorrect stack height due to worn friction plates (the steels don't really wear appreciably)
2) incorrect spring length also due to wear
3) issue with the pushrod and/or throw-out bearing

The clutch slave could also be an issue but since the bike is new to your buddy and is over 10 years old, this is less likely. My money is on a worn clutch with possibly a pushrod and/or bleeding issue (not suggesting operator error in bleeding, it's just these bikes always seem to have air or water in the lines)

 

I'll try to get some pics/videos up soon. I do not have a manual he was previously riding this regularly for a few weeks before we took the pressure plate out and only 3 of the plates when we noticed they were in need of some replacement. I put them back an reassembled it now I'm here lol

 

Ah, well then if he was riding it before with no issue then I definitely suspect the pushrod. Sounds like nothing was changed so something had to have happened during reassembly and something isn't sitting right.

 

Yeah, something this not assembled correctly if the lever is binding up. Take the slave off and press it all the way in then reassemble.