I swapped out the clutch cable and all went well I think. The problem is that now the transmission cover does not fit back on snuggly. I can't seem to figure out why it doesn't fit now, everything was put back in the same way...I think. If anyone has suggestions please help me out...thanks.

 

Take derby cover off the primary and slacken off the adjuster in the clutch (all the way, take it our completely is best), wind the cable adjuster in fully and then try again, if tranny cover goes on you then adjust the clutch as per the manual and it should be fine.

 

I did this when I changed the cable. Everything is as slack as possible and the cable is screwed into the transmission all the way. The primary cover is what doesn't fit back on now. I'm getting very frustrated with it. It's the last step to get riding again after an internal wire bar swap. Anyone other suggestions?

 

I had this same issue with the transmission cover after swapping out a clutch cable. It would not sit flush. I forced it on somehow....this was the WRONG thing to do. When I replaced the cable again and removed the cover, the inside was all chewed up with metal chips just hanging off..there were metal chips in the tranny oil too.
The reason it wont sit flush....the orientation of the cable connection on the clutch ramp is wrong. Find a pic of the clutch ramp with the cable connected..make sure yours is set exactly the same, then install the cover...it should go on without forcing it.

 

Correct. You have the clutch ball/ramp partially engaged. Pull the cover off, put as much slack in the cable as you can and make sure that the ball/ramp is pushed all the way back then reinstall.

 

Retaining ring open end position:



Clutch ramp/cable position: