RXS100 Clutch Problems - Help!

[Yorkie Bar Kid]

Im having some problems with my RXS100

All started last week when I replaced my clutch cable with one form a spare engine. When I transferred the cable over I noticed that the spring that keeps the tension on the cable was knackered, so I just transferred over the cable a left inner crankcase from the donor engine and had problems with the clutch still.
I noticed that the pushrod which operates the clutch was slightly bent where it comes out past the oil seal. Fortunately I had a spare pushrod with the donor engine so slapped that in and everything was fine. However after riding in the rain the clutch seemed to stiffen up slightly.
I changed the gearbox oil over today and while I was at it I checked the pushrod. The rod is fine and perfectly straight, I refitted it into the engine and replaced the crankcase however when I came to operate the clutch it was ‘notchy’ and the clutch would not disengage fully letting the bike creep forward in 1st. I had another look and removed the crankcase to check the rod was on correctly. Placed the crankcase cover back on however this time the clutch lever was just solid and very very notchy. Checked the cable clearance etc its only when the case if flush with the engine that I have problems. I don’t have anther pushrod to hand.

Does anyone know why the clutch is so stiff?? The gearbox fluid is right up to the top where it should be. I have checked cable tensions and they seem fine.. any advice??
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Blues and Twos in my rearview.

[MarJay]

Could the clutch basket be notched?

Either that or the cable needs lubing.

It does sound like the clutch plates have made notches in the clutch basket making it hard for the plates to move.
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British beauty: Triumph Street Triple R; Loony stroker: KR1S; Track fun: GSXR750 L1; Commuter Missile: GSX-S1000F; Cheap project: CBR900RR FireBlade
Remember kids, bikes aren't like lego. You can't easily take a part from one bike and then fit it to another.

[Yorkie Bar Kid]

I will have a quick look and see what can be done.

the cable is ok, it has been funny lubed and works normal when away from the pushrod... its worth noting that the last pushrod was bent don't know why yet
the clutch operated fine when the new pushrod was installed it just seemed to go funny after been out in the rain. it seemed to work ok until I inspected the pushrod

i got Haynes to refer to but it doesn't mention my problem lol
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Blues and Twos in my rearview.

[Paddy Blake]

Have you adjusted the part at the engine before you adjust the cable.
There should be a screw with a nut on it that you adjust in then turn it
back before you adjust the cable.

Paddy.