So I bought a brand new ACT HD pressure plate and sprung 6 puck clutch kit and an ACT streetlite flywheel, new TOB from the kit. I install everything using the instructions from EVO moto, I pull back on the clutch fork to engage the TOB and it wont engage, I look thru the access hole and I can see that the wavy springs on the front are compressed and kinda stuck, so I get a flathead in there, get them un-stuck, engage the TOB again, this time it catches, I then apply a small amount of force on the fork pressing the same direction the slave would, bam, the TOB pops out again.

I take the whole thing back apart, I replaced that whole retainer spring assembly in the middle of the pressure plate with another one from a good condition stock pressure plate and use 3 wavy rings. Press it back and forth before install, feels good, doesnt bind, I attached it to the TOB with the trans on the ground, it engaged good, so good it was a bit of a PITA to get it disengaged. I re-assemble it all, push on the fork, TOB engages, YES finally. Do the same as before and put a little pressure on it by hand, TOB pops out of the pressure plate again and sends the retainer clip/ring flying off. Take the whole thing apart again, put it all back together, I made certain the input shaft did not hit the pressure plate when installing it (I pulled the motor from the car to attach the trans to the motor on the ground rather than wrestling this biatch laying on my back). Get it all back together, clip pops out again. WTF am I doing wrong? I am really getting frustrated with this thing.

 

Well I finally got this thing to work. I took a lot of patience and 5 wave springs to get it done.

 

I have the same issue right now and i think I am gonna have to take down the transmission and undo 19 hours of work.

 

thats why I pulled the motor from the car and did it all on the floor. I disconnected the p/s pump and A/c compressor, pulled them out of the way, disconnected the downpipe and just pulled the engine. Its a ROYAL PITA!!!