The clutch has not been adjusted correctly since installation or the clutch has never been adjusted during any routine service. The clutch thrust bearing and the diaphragm of the clutch cover pressure plate assembly have worn indentations into each other.
- All care should be taken when replacing bearing carrier on the clutch fork. Also ensure the retaining spring clip has sufficient tension.
- Always work clutch thrust bearing carrier both forward and backward to ensure that the fork is retained firmly on the carrier saddle.