Motorcycle Repair: Clutch issues, clutch master cylinder, clutch basket

Question
Hi Paul,
I have a 1987 Ninja 1000R. 20,000 mi & in excellent condition.
In the last year, I`ve had a used clutch assembly installed(original blew apart) , new clutch plates & had the master cylinder rebuilt.
If the bike is on the centerstand, I can shift up & down the gears w/o the clutch, and clutch will not disengage.
While riding, it will disengage just enough so it doesn`t stall at a stop. While riding, I can shift w/o clutch.
What am I missing? I`m afraid that eventually it will start stalling at stops due to clutch not disengaging.
Any thoughts are appreciated.
Thanks in advance.


Answer
First make sure the clutch master cylinder is bled correctly, air in the line will not let the clutch disengage fully.Second,if #1 didn't work, the clutch needs to be disassymbled and the parts inside need to be checked.You need a parts diagram to verify that all the necessary washers and spacers are present and in the correct order. There are thrust washers, 2 clutch pushrods, and a bunch of washers and spacers that need to be installed in the right sequence. This applies to the installation of the clutch basket and hub, the clutch pushrod and thrust washers, and the way the plates are installed...any of these three areas could have been installed wrong and the clutch could have the symptoms you speakof.