I have everything installed. 4 clutch springs, thrust washer at the back of the clutch pack, and the washers behind the lock nut on the shaft. The only variance I can think of is using 6x30 bolts instead of 6x28, but even then it's 2mm difference, and I added a washer to the back of each bolt, so it should effectively be 28mm in length.

My dad thinks it's the pushrod in the clutch cover that's bad. Again I have no idea how many times the other idiots before me screwed up a fairly simple clutch job, or abused the hell out of it in other ways.

 

Your dad may be right. When dealing with stuff like this, it's best to assume that nothing is correct and go from there. Go through the entire basket piece by piece, bouncing it against what the manual states.

 

So a few months later and I took the clutch out again and even took out the drum to see if there was anything missing or improperly aligned. Nothing out of place, and the clutch still doesn't disengage. Play also looks about the same in the clutch arm. Gonna get a piece of stainless steel and make a new pin and see how that goes.

 

Currently have the clutch out for like the 3rd or 4th time now. Nothing is missing, and even making a new clutch push rod hasn't solved the issue. Right now we're trying to see if we can even get the dang thing to disengage outside the bike. Currently it seems like there is no play at all in the clutch. (As in we can manipulate the clutch to get seperation even without the spings in the basket.) Is there a post or video explaining how this particular clutch is supposed to operate? I'm completely at a loss for what I should be looking at right now.

 

Try taking a pair of plates out.

This should show whether it’s the mechanism jammed or the basket is really over full.