what the frick. clutch won't release.

I put my starter clutch back together today and put the cover back on, and then put the clutch cover back on.

Something told me to make sure the clutch worked OK...well, I checked it and it doesn't. The clutch doesn't release when you pull in the clutch lever.

Was I supposed to do something in particular when I put the clutch cover back on?

Was the clutch release mechanism installed correctly?

Clutch mechanism...

I never took it apart or did anything to it. All I did was disconnect the cable when I took the cover off.

Yes,but if you didn't have that release set up properly when you reinstalled the cable,then it won't apply any pressure to the clutch-rod,which applies pressure to the clutch plates.

What I mean,is that the mechanism has to be positioned properly when you install the cable,and put the cover back on the engine.

OK well I wasn't aware of that and that's what I was wanting to know...so how exactly is it supposed to be positioned?

It feels like it's putting pressure on the clutch rod. I dunno.

How does it feel at the lever?
Does it feel like it did BEFORE you pulled it all apart?
Does the lever pull in with the same resistance as before,or is there slop(play) in it?

The final clutch adjustment(numbers 1 and 2 in the pic I posted)...you might have to do some adjusting there,perhaps.

It pretty much feels like it did before, yeah...No slop, has about the same resistance.

Also...well, it's hard to get at the adjuster because someone who had the thing previously rounded out one of the screws that holds the cover on for that...and I'm not quite sure how to get it out (I don't have a screw extractor). I would cut a slot in it but I won't be able to do that without cutting the aluminum around it.

You're gonna have to get that cover off,Garrett...for sure.
You need to rule that adjustment out,with what you have going on right now.Sometimes,it only takes a slight turn of that screw to make a world of difference.

Not saying that THAT'S what's going on,but you have to get in there to see for sure.
Do you have an impact screwdriver?
Can you use another type of screwdriver,and tap it with a hammer(gently) to get it to bite?

This will be a final adjustment,after you've ruled out all other possible causes.
Lets not forget that worm-geared clutch release mechanism either.
If that wasn't positioned properly when you put it back together,then that will cause problems,like you're describing.
As soon as you disconnected the clutch cable from that gear,it may have moved to a different position,and you may have moved it to another position(wrong position)when you put it back together.

Well, I'll have to see what I can do with it tonight.

How IS the clutch release supposed to be positioned? I have a service manual that just shows a picture and says "position it like this" but the picture really doesn't tell me a damn thing.

Can't say for sure,Garrett.
It's more of a hands-on procedure.
You have to position the part that rotates,to where it is about mid way in the other half of the work gear.
Turning it out too much or not enough won't work.It has to be in the mid range,approximately.
And you HAVE to get that cover removed,so you can do a final adjustment on the clutch,there.

And don't forget...we might not even be looking in the right area,as you could have an issue elsewhere,but lets get this part figured out first.