Replaced clutch cover on a gasgas 250 pro 2008 for a Raga one. When all the Allen bolts are tightened it makes the kickstart stiff, and it doesn't always return properly. If the 3 bolts closest to the shaft are backed off it seems ok. The old gasket was used, could this be the problem.

Did you refit the washer to the kickstart shaft? Check on the old cover, might be stuck on that still

Yes double checked that washer was in place.

It is real easy for the kick start shaft to move out a mm or two. Sometimes it is very frustrating to re- fit.

And make sure you lay the bike on it's side when you mount the clutch cover, to make sure the clutch parts stay in their place...

Is there a groove in spacer that fits over return spring that's not lined up? Or am I thinking of the older engine....