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look at your clutch actuator, if it's almost impossible to pull, something not right. Are you sure you didn't rotate the arm the wrong way? I've done that myself a few time and it's easy to overlook.

Ok, i think I got the bastard fixed. I took the new springs that came with the clutch kit out and replaced with the old ones..... The rear wheel spins, in gear when the clutch lever is pulled in.

Soooooooooo after all this dicking about and buying a new clutch kit all that was wrong with it was the $4 washers where missing as posted on page one. But because the clutch kit I purchased has the wrong springs it totally stuffed me up! I'm going to order OEM springs. So I wasted $80...... At least I can rebuild a clutch with my eyes closed now.

I'll know it's fixed for sure tomorrow after I fix up the gasket and fill her up with oil and ride her

i really doubt the spring were the issue. but glad it's fixed now.

Hmmmmmmm perhaps. I guess when I changed springs something was reinstalled slightly different which made it work. Well I sure as hell ain't pulling it apart again lol

Thanks for all the suggestions guys first time I have worked on a clutch. Every bit of advice helped and maybe in the future this topic can help someone else.

Year old topic, but i'm having the same problem, what was the end result. Did the cluth r-n-r work? Was it just the washer? Did it stop sticking?

If that's an aftermarket clutch you should not be running the Jada springs. Try that.

Some spring kits are for a number of different bikes, some use 5 springs, some like the KDX use only 4. This is normal. After your 4th set you get one free!