Hi everyone. Need some help with clutch disengagement issues on XT660X. With the engine in first gear and clutch lever pulled the clutch won't disengage and the back wheel can not be stopped. I tried to take all the slack from the clutch cable without any improvement. The pull lever and casing dots are aligned with the pull lever all the way forward.

I opened the clutch and found out that friction plates are not aligned as per the manual and not in the right order. I decided to disassemble the whole clutch for inspection. I found several things that may not look right

1. After removing the shaft nut I could see that the boss is not all the way in on the shaft splines. I haven't seen disassembled clutch on XT660 so I can not be sure but it does not seem right to me. There are maybe 2 mm from the end of the shaft splines to the front edge of the boss

2. I could not remove the boss by hand. It would move about 3 to 5 mm and then it will stuck. I had to make a tool to force it out. Similar thing on reassembly. It would not go in on the shaft. I had to heat it up and even then I had to force it in

3. The spacer/washer with splines that goes between the boss and the basket is going way past the shaft splines and dangles around the shaft not being in center with the shaft

I reassembled and installed the friction plates in the right order and position, but the issue is still present. The clutch won't disengage. Some of the pressure plates had discoloration like from excessive heat but they were not wrapped. Same thing with the spacer/washer, at some parts there is discoloration.

What could be wrong here? Any advice what to check?