Very similar situation here. (2010 Streetfighter 1098)
My EVR clutch upgrade didn’t go all that well either… I spent 3.5 hours at the mechanic messing around with the clutch and no matter what the guys did, they couldn’t get the clutch to work correctly. Mind you these are the best Duc race techs in the area.
It seems that the stack as it came from the vendor, is too high for my case, and I never get the full deflection on the pressure plate, and as a result, I can't switch into neutral, or it is almost impossible to switch to neutral. When we put the stack together the way it was in the instructions, it was almost impossible to put it into 1st and it would actually drive with the clutch level all the way in. Then we replaced all 2mm steel plates in the EVR stack with 1.5 mm stock steel plates one by one and I still couldn’t get into neutral. Then, we took out the concave steel plate and replaced it with the stock wave plate…now the neutral is possible but VERY difficult, I can get it into neutral maybe 1 time out 20
Measured the throw of the pressure plate with the lever fully pressed and i was getting full 2 mm less of deflection then the stock. By adjusting the lever free play and also shortening the lever itself (i have one of those wonky adjustable length levers) we got some additional 1 mm of the clutch plate deflection, which made things somewhat better.
My mechanic is telling me the last thing I can do is replace my Evoluzione clutch slave with the stock one, and then MAYBE I can get the clutch to work.. I thought of getting a 1 mm steel plate, to put place of one of the 1.5 mm, but they are not available for newer models, only for some bevel driven ones, the 1970’s model Ducatis. It could also be possible to get a couple of 2.5 mm friction plates install them in place of one or two 3 mm ones, reduce the stack height and then get my clutch to work?
But then again, by reducing the stack height, i am eventually going to go into clutch slip territory and render the clutch inop altogether.
Someone told me I could shim the pressure plate by putting a steel washer between the clutch push rod and the pressure plate and get some additional deflection on the pressure plate and get the clutch to work, but my mechanic is telling me it is not going to work and will possibly reduce the life of the clutch slave considerably. (makes sense)
Changing the clutch slave to stock is the LAST thing I want to do, but my clutch is not working correctly and I am almost out of options since the neutral is almost impossible to get into and the bike shift gears only at the speeds above 15-20 mi/hr. My clutch slave is the smaller one Evoluzione had, the 28mm one I think, not the 30 mm.