Rebuilt clutch. Now throwout lever hard to spin.

On my '82 Maxim 750, the clutch throwout shaft is really, really hard to move now, after just rebuilding it.

Here's what happened: I rebuilt the clutch - basket was fine, and stayed on, other than smoothing out the rub marks. I added new OEM-style friction plates. The plain steels are all unburnt and flat. I replaced the outer pin bearing and the outer oil seal on the throwout shaft. The shaft spun in there fine, when apart. I added a new pull rod, washer and wafer bearing. Everything soaked in oil for quite a while, and I put it all back together with no problem.

I closed it up, and started to put the lever on -- at that time everything seemed to move fine.

Then I realized, Oops! I forgot to line up the dots on the pressure plate and basket. So I opened everything back up and put it back with the dots aligned.

But now, when I put on the lever/cable perch I realized it no longer moved well. It doesn't matter what gear the transmission is in. I can put a screwdriver tip into the cable perch and move it with the screwdriver shaft anchored against the other end, for leverage. With effort, I can move it by hand, too.

What the heck did I miss? Your thoughts? Before I order a new gasket and take things apart again? I haven't added oil to the case yet, but I wouldn't think that's it. I could move it fine before I took it apart (and after oil had been drained).

I think I've pretty well described the issue, but here's a quick video showing how stiff it is:

 

Well... ok. I think I just cried Wolf for no reason. I Did just go ahead and open things up again. I’m pretty sure the gear was just not meshing to the inside gear of that shaft to line up correctly with the other piece. I have it angled down in that direction but maybe there’s a trick to get these together?

Seems I managed with just some shimmy and shake and wiggle and its still a little hard to move.

 

It's not supposed to move easily. Moving it by hand pressure alone will be nearly impossible.

Put the cable on and adjust it. Does it move fine then?

 

Ahh... I thought it'd move more freely than that.
I've got a new cable on, but I'm stuck for the moment without any motor oil or cable lube, until the shop's open tomorrow.

I did attach the cable anyway and adjusted some to see where things landed. Still seems pretty off. Hard to pull, and a huge amount of free play.

I stopped there for now.

 

Mine was tight after rebuild.......you are fine.....line up the alignment mark on the lever/cable perch to the mark on crankcase , attach cable & adjust for appropriate tightness, and ensure that clutch engages & disengages thru all 5 gears with a ride....

 

There is quite a bit of free play in the system(gear lash being the main contributor). The cable adjustment will remove most of it.

From back when our favorite poker player was putting his new clutch in:
Reassembly of Clutch Cover - '82 XJ750J Maxim

 

turpentyne......look at k-moe's link above.......Rick-o-Matic and BigFitz offered great advice on the clutch cable & lever and getting it right.......

I follow their advice and it worked out great.....

Thanks k-moe.......I forgot about my trials & tribulations back then......a lot of guys provided me with tremendous help back then especially yourself .......

Thanks for all that you do helping others as well as me over the years.....