I have a 02′ 400ex, I put a new Tusk clutch pack on, with the HD springs. I soaked the fibers for a few hours, took them outta the oil (yamalube) wiped off the excess and installed them on the quad as per the service manual.

I tightened the springs down till snug and went a extra quarter turn, no torque specs in the service manual.

The cover is kinda a pain to put back on, its hard to tell if my lifter is really engaging but it seem like it is.

Problem is the clutch won’t disengage. The lever feels snug, has a little play and when I pull it, it seems like its properly actuating the lever but when I click into first from N it lunges like the clutch is not being pulled.

I went back and pulled all the billion bolts back out and re checked it and it all seemed good but I dunno what would cause this? The clutch baskets are not worn, they were just out and inspected.