So I looked at your pictures. Show us how the pin sits in the crank from a side view. Most rods only needed 18 thousands clearance. Granted I have luckily not done a bul.
In case they have not told you, the pressure plate only goes on one way. On the clutch one of the posts will have a notch in the end of it. That aligns with a mark on the pressure plate. Good luck.
Trailercamp the issue you are describing is you had the lever adjustment too far in which stops the piston from traveling its full range. You fixed a 27 yr old problem?
Remove the rear brake pedal comepletely. Use a phillips screw driver to pump it. You are far better off with a clear tube over the rear fender. The air will not move until the fluid is above the master cylinder about 8 inches.
Search on you tube for jim snell video's. He makes one for the clutch only. For 1995 thru 2001 models. You should be able to see what you are looking for.
I was passing a motorhome in Yellowstone on an xl 350 and almost hit a Grizzley that was running across the road out of my view. Scared the crap out of me. Luckily he was at a full run out of there.
https://www.redlinestands.com/catalog/shop-equipment-c-327/tire-change-equipment-c-327_331/tire-changers-c-327_331_248/discontinued-coats-220-manual-tire-changer-p-1865
I had this manual changer for over thirty years. Lubed every tire I ever installed. All trials tires I could usually mount just by hand. Street tires were just as easy. Some of those rock hard knobbies were still the worse.
Wish I still had it, but I quit working on bikes for the most part. Just my own. With all my grand kids growing up, it's still would of been usefull!
.
Don't need soap or water with mounting a tube tire except to test for leaks and to wash the wheel before you work on it.
Edited yesterday at 06:09 PM by lemur
The canuks must use Moose urine! Mounting a tire without lube is lunacy at best!
Is it a tubless or not? Just putting a tire on is pretty simple. Alot easier if you heat the new tire up first. Laying it on the dazh of your vehivle is the easiest. Some sunshine needed. Soap and water mix and lube well. Lots of vids on it. Good luck.
You are asking someone from 5 years ago? You will be fine, bend your knee`s a lot. Trials is about body english, Use your body a lot to make the bike move. It will take a lot of practice at your age, but it is worth the fun involved. Good luck. I am the same age, but I was an expert at 14!