I replaced the clutch in my 03 600rr. When I first got it together it was still slipping. I took it apart and put it back together it worked fine. Clutch engaged nicely and was working fine. Rode a few miles realized my case was leaking quite a bit actually. I oil light didn't come on or anything. So I stopped riding and took it apart and resealed it. I didn't touch the clutch at all. Just the bolts in the case. When I put the case back on. The rod would engage the the clutch pin but it seemed as though the pin wouldnt move and the lever that the cable attached to would move to engage but then would stop and not move the clutch at all. Any idea what I did wrong?

 

Did you turn the lifter to the left as you replaced the cover

 

 

Then it can only be cable adjustment

 

 

Then I would strip it all down and start again

 

After rebuilding the clutch at least 100 times, the problem is resolved. I hit up a couple FB groups. They told me not to worry about it and just throw the cable on it. I was worried it would stretch or break the cable. But I listened. Put it all together and voila. WORKS. The cable and the lever provides way more torque than I could get on it with my fingers. Turns out the new clutch springs and the new return spring made it pretty stiff. However the cable and lever was enough to handle it.

 

Seems it was the cable, you wont move that with your fingers only

 

 

Did you really think you could shift 4 clutch springs with your fingers, evidently you know nothing about how the clutch works, take it to a shop next time