I was going to suggest a lack of grease inside the throwout bearing to fill the recess that goes around the inside circumference of the bearing, and the mating surface of the collar that is on the tranny. You also need grease on the inside splines of the clutch disc. The splines of the tranny look dry to me but I know that you said that you greased all of the parts, mabye it is just hard to see from the pics and I could be wrong. The splines of the tranny shaft fit inside the corresponding splines of the clutch disc and the need some lube.

 

Got it. It's all greased up now! Will finish everything up Monday morning. Just hoping this problem won't come back!

 

Sorry I mistakenly said the splines of the flywheel, I meant to say the splines of the clutch disc. To grease the splines of the disc you have to extend your longest finger past the throwout bearing to reach the inside splines of the clutch disc. I will go back to amend my earlier post.

I got the tip to fill the inside recess of the throwout bearing so that it is level with the side surfaces from Billman250, apparently that keeps it lubed for the life of the clutch.

The other parts to be lubed are listed in the shop manual, just be careful not to lube the other parts too much, a light skim coat is sufficient to prevent the grease from flinging off onto the clutch friction surface.

 

did you ever get it fixed or find out what the exact problem was because I am having the same issue now

 

Has your clutch been recently replaced?

 

If the slave and fork all look normal I would start investigating the PP and how much it is actually disengaging. As well as making sure the fingers all look uniform and normal. Check the HD Rivets that connect the plate to the finger diaphragm.

Maybe you could also have someone hold the clutch and someone spin the engine while one uses flashlight and watches the PP spin while all installed.

Personally the parts that are new already like the TB and stuff shouldn't need replaced, I'm guessing your stacked height is a little tight, ie. the the PP isn't disengaging far enough or not uniformly.