I bought an 01 GSXR600 last winter to be a track bike. The clutch pull was very stiff when I bought it. It had been down on the left side and the cable had been pinched. So we thought that was the issue. New cable, no help. So I pulled it all apart and checked the smaller parts. The screw assembly was missing a couple of the bearings. So we replaced it and the return spring just because. It got a little better after that. The plates are all in correctly and the springs have been replaced and are torqued correctly. We've adjusted the cable and gotten it to be a better pull. But it's still a lot of grunt to get the lever back. I've had and ridden older Suzukis, and newer Hondas, Ducatis, Harleys, Triumphs, and BMWs, and have never had a clutch that took this much effort to pull. I'm having a hard time imagining more than 1 track day at a time, and wondering if I'll even make it a full day without my left arm being on fire. I'm not a gym rat. But I'm not a weakling. Is there anybody out there that knows what I can do to make this clutch pull more easily?
All I can suggest is to keep working through the system. Some thoughts (you may have already checked some of these): -check the clutch perch and lever for correct operation (not pinched / no drag) and ratio. I've seen replacement parts with the wrong ratio increase pull effort, or cause disengagement issues -which clutch springs did you put in? I find many of the aftermarket springs very strong and hard to pull. I prefer OEM most of the time. -check that all pull / operational angles are properly aligned for easiest pull. No line pinches obviously. -check the clutch basket to make sure it's not warped or mis-shaped. -verify all moving parts / shafts / etc. are straight, move freely, and aligned. There's no magic here. It sounds like you just need to find what's causing the high effort. Good luck. Matt