I just finished the 1.6 conversion, used 1.3 head, 1.3 flywheel and 1.6 starter.
installed low range off road conversion adapter, with 1.3 clutch kit.  new T.O bearing etc.
the problem i have now is that even eliminating the clutch cable, (moving the clutch arm on the trans by hand) the clutch will NOT disengage.  do i need to do something to compensate for the 1/4" adaptor plate? is the throw out bearing now too far away from the clutch disc? please help, ive got the bolts out and about to drop tranny again again....ugh




btw....engine cranks fine....just drives with the starter while in gear starting, and clutch down

I don't know much about the conversion kit, or how the clutch actually works (I've just replaced part's A, B & C with new A, B & C parts when doing clutch kits). But, I do know Low Range Offroad has a good reputation with their customer service. If you got the kit from them, I'm sure they'll be more than happy to help you. I believe their Suzuki Guru is Sean, but don't quote me on that.

can you turn the clutch release arm on the side of the tranny to get more pressure? or even to shorten the arm movement.

I know that it doesn't take much to make the clutch not work. Some poeple will turn the flywheel when replacing the clutch and end up with some problems. My friend got it turned and the clutch would not work good. I gave him an old flywheel and it worked like a charm

Are you sure you put the fiber clutch plate in the right way?  It is quite obvious if it is not installed correctly, but people still put them in backwards.
TO bearing that slid off the end of the shaft and not letting the clutch disengage could cause the problem too.
Is there some play in the arm with the clutch cable disconnected from it?
The 1/4 adapter plate should not cause any problems, since you can adjust the cable to compensate for it.

yes, there is play in the arm without cable attached.  i pulled trans off, lever moves the TO bearing freely, actually too much to the point where it gets lodged on the end of the shaft. i assume with clutch in, it could not go that far. I put the clutch in springs to the tranny...very frustrating to take back out. i always pull motor and trans together cuz it is so hard to get trans in and out and hooked up under vehicle, especially with the header, which btw is lodged between frame and bell housing...

What did LRO suggest?