Hi Bushy,
First up have you got the clutch springs set to the correct tension ?
With the clutch disengaged, depress the kick start, does it spin true and does the top pressure plate lift squarely or is there a wobble, tension up the springs to give an true run, i.e. no wobble
I would keep the chain-case off untill you can crank the engine over using the kick-start, at least this way you can see whats going on and you will be able to see if the clutch is slipping.
Second, the oil in the primary chain case should be sae20, Castrol lite was recomended but I have not seen this for many years so I use AWS 46 hydraulic oil, made by Castrol
If the oil you have used is too heavy the clutch plates tend to stick together making it impossible to disengage the clutch
If the oil is to heavy you can clean the clutch out using paraffin oil (kerosene) then refilling the chain-case with the correct grade oil.
As you state you have clutch slip I can only think you have not adjusted the clutch correctly, if you have the correct
slick-shift gear-box fitted you may have the slick-shift mechanism out of adjustment.
I replaced the clutch on my Tiger 100 using synthetic inserts and have run with hydraulic oil in the chain-case with no problems. Just remember to change the oil at regular intervals, to offset the effects of condensation.
H.T.H. Regards TripleGuy
