Clutch will not disengage

[Monty]

Mate with a standard 4 plate clutch has just changed from a 150 gearbox to a GP200. He left the hub and wheel on when he swapped the box and had to go down shim wise from a 2.00 to a 1.7 he says.
Refitted the original clutch that he has run for ages but found that his new Christmas tree was not centre drilled to take the shaft on his basket so he has cut it off. Its an LI/SX type with the nipple as was the original. When he refitted the chain case the clutch cable is 1/2 and inch slack. even with a spanner on the arm and the scooter in gear he can not kick it over. If he removes the chain case side and puts a clutch compressor on it only moves in by about 3-4 mm before it slips, Had it apart 2 or 3 times, separated the plates and oiled them up but its still not slipping.
He wont rebuild it till it slips
Any ideas

[Monty]

well last night he rebuilt it with the original box and the basket and it still wont disengage
He is doing this with no oil in the box to save draining it out as he has had the chaincase on and off like a yo yo.
I am suggesting its dragging though it doesn't when he uses the compressor

How much travel should he have on the clutch arm? his is the same as mine

The arm moves up to around 2 min to 12 with no slack and will go to about 5 past 12 with a spanner on the arm, that pushes the chaincase off by around 5mm so should be pushing the plates in by the same amount.
I am telling him to put it together fill up with oil and try a gear with the brake on to see if it slips or stalls

[joespeed]

did you get this sorted out?

[Monty]

Yes
he could not get away from the idea that he should be able to put it in gear and pull the clutch in and it should kick over
As he had had the chain case off about 20 times he also refused to put any oil in.
In the end he let me adjust his clutch cable, the trunnion had slipped down the cable and put oil in and without the exhaust on, start it up. He was concerned that it was pointing at his 5 series BMW but went inro gear as it should and was fine.
Too many preconceptions of what should have happened, 3 days work and he is back to where he started but with a 150 box and a 46, 17 combo
He had a perfect Iron 200 lump and opted for a muggy 225, big carb etc and is still struggling to get what he had before he started, its been to every shop in the area, he carry's a load of chrome and rides 2 up and was always reliable as hell. he is a grand down and still not happy.

[bristolmod]

he'll learn.......................eventually

[sean brady scooters]

perhaps he should be more concerned about engaging /dis engaging his wallet ..

[Monty]

perhaps he should be more concerned about engaging /dis engaging his wallet ..

He had it dynoed and was told it would pull better on a GP 200 box so bought one along with chain, 47 sprocket and could not believe that he got as near as dammit the same ratio from his original box with an 81 link chain a new front sprocket I had in the draw. I told him to run it and see, (never anyone to do the "try before you buy" when I need it) Last I heard, still not happy so he is running out of options, he has more torque than he had but talks about 70 plus should not be a problem, 2 up with half of B&Q bathroom fittings

[byron]

...but found that his new Christmas tree was not centre drilled to take the shaft on his basket so he has cut it off.

shame. I like to use them whenever I can