There is a push rod, a round bushing, a bearing and a piston that make up the clutch release assembly. Unless you have an incorrect part, there must be another problem.
When pulling the handlebar clutch lever, does it move the end of the piston? Is the clutch cable adjusted according to the instructions? Is this a stock clutch or an aftermarket or a Southland?
Clutch disks have been known to stick and not release, but normally only after sitting for a while in a damp environment.

There is a push rod, a round bushing, a bearing and a piston that make up the clutch release assembly. Unless you have an incorrect part, there must be another problem.
When pulling the handlebar clutch lever, does it move the end of the piston? Is the clutch cable adjusted according to the instructions? Is this a stock clutch or an aftermarket or a Southland?
Clutch disks have been known to stick and not release, but normally only after sitting for a while in a damp environment.

It started with old clutch. Put new clutch in complete and new push rod the throw out bearing is good. The throw out bearing or piston does not extend out to end of transmission at least1/8" inside. I checked a 92 and it sticks out past the end of the transmission. I was wondering if it could be a bad flywheel or crankshaft end play.

It is a stock BMW clutch

You indicated the issue started with the old clutch in there. If you replaced all the pieces of the clutch assembly and the still the problem is there it has to be in either the transmission , linkage or motor. I am not sure when the circlip mod was made to the transmission, maybe someone will chime it but maybe there is a shaft that is moving. How did the input shaft feel when you had the transmission out? Did you replace the diaphragm spring part of the clutch, that seems to create the stopping point for the release rod?

The input shaft looks and feels good. It does have a new diaphragm spring. I am thinking the flywheel or crankshaft end float it seam like the spring is to far away from the transmission

I am attaching a picture of the flywheel. The raised portion of it where the diaphragm mounts would have to be collapsing in order to create this condition, did the unit seem solid and in good condition.

If yours have issues, this picture came from an e-bay listing, 231307188552 great price.

The flywheel looked ok to me but this is the first time I've seen one. I looked for a measurement on the height but haven't found one yet.

The parts all looked the I measured everything and part numbers match. I will look at snowbuns site.
Thanks

Did you have this problem before changing the clutch? The push rod could eat out a hole in the spring, but if both are new this does not seem likely. Is there any way the rod could be installed backwards or is the piece that fits between the rod and the bearing missing?

Bob

Did you have this problem before changing the clutch? The push rod could eat out a hole in the spring, but if both are new this does not seem likely. Is there any way the rod could be installed backwards or is the piece that fits between the rod and the bearing missing?

Bob

This bike has the new style throw out bearing they call it a piston and a new style pushrod nothing between then that I no of. Looked at a 92 and that is the way it is also I think.

Does your clutch rod have a step machined on one end for the release bearing to push against?

Yes and I think all the parts taken out were original.