OK, after screwing around with this for weeks (I've been busy at work), I managed to take the inner and outer clutch basket out and check everything. I think what happened is as I explained: the innermost clutch plate jumped onto the judder spring and bound the whole thing up. After talking with a 919 engined car racing team in the UK, I removed the judder spring and spring seat, and I replaced it with a regular clutch plate. I then buttoned everything up....

Finally, the clutch disengages as it should. This is a huge victory because I was looking for a replacement motor. Thanks to all for the suggestions. Now, it's back to f cking around with the clutch cable.

--Chris

 

I'm in the process of trying to fix my clutch now. Same problem that you had. My inner clutch plate does not seem to be binding up everything, though. Does your center pull pin have a lot of freeplay between where it seats in the shaft and the bearing in the pressure plate? With mine, you can move it in and out about 1", before it contacts anything (seat in shaft or bearing in pressure plate). I have a feeling that my problem is the clutch springs. They are only 43mm tall. The manual specifies 48 to 50mm.

Since you had yours appart a few times, any insight you can give me would be appriciated.