clutch problems

if the pads are not worn out, I'd start by putting everything back the way it was and looking at it real closely - it may be that the arm needs to go a couple splines back on the shaft or the hub isn't seated deep enough on the shaft, or maybe the internal spring needs an adjust

i had the same issue with mine and came to the conclusion that it had nothing to do with the bucking bar, pads or adjustment... it's simply with the amount that we use the clutch, specially for starts from a dead stop where the clutch actually spins the bucking bar, it wares out the sides of the clutch shaft to a point where the clutch arm simply pushes the bar to the side rather than into the shaft... it's a $5 fix for the new shaft from bike berry on ebay... not sure what they charge on their actual page... but i'm pretty sure that by replacing the shaft, then setting everything back to relatively stock settings, you should be good to go, i'll let you know for sure in a week or so when mine comes in... i too replaced the bucking bar as well as the cam due to the fact that they were completely worn out, but when replaced, the problem didn't go away, it actually seemed to get worse... that was when i pulled it all apart again (several times) on my ride home and realized that it was the walls of the shaft that had worn out almost 1/16" all the way around, so the bucking bar would NOT sit straight... i don't know if anyone else has had this issue or not, but as i said, i hardly ever pedal start aside from actually starting the motor... once it's running, i treat it like an actual motorcycle for starts, which leads to excessive ware on the shaft walls...

i did get probably 2000+ miles out of it, but thanks for the heads up

I have been noticing a lot of slop in the covers where the clutch throwout shaft rotates on really high-mileage engines. The casting is showing wear so the hole is sloppier. But aside from being annoying, it does not affect much except cable adjustment so far.