I replaced my stock clutch fork with a new one, and haven't had any further issues. Its funny you mention a chattering clutch, as I'm convinced the POS Ram HD clutch I had in (this was about 5 years ago), which chattered like hell, had a lot to do with the fork breaking. I went to a McLeod Street Twin, and while it was like an on/off switch as you describe, it didn't chatter at all.

 

Yeah man, I know it's the chatter that is killing it. You can learn how to deal with the chatter and even ride it out to some extent, but it doesn't make it any easier on moving parts. A little chatter isn't such a bad thing, but in Houston it takes me an hour to go 20 miles to and from work, so there's a lot of off and on the clutch.

 

Atlanta is the same, probably worse...chatter is something I won't put up with!

 

I've run a Spec stage 2 and it wasn't chattery at all. Now there's a stage 3 in there and clutch pedal doesn't feel bad at all! No miles on it yet, but I find it odd that the clutch was so hard for you to push in. It sounds like something wasn't aligned quite right. Oh, and I suggest you buy a whole new hydraulic asembly including master and slave cylinder: It's a snap to install and they only cost about $125 or so from Gmpartsdirect or else from Dal Slabaugh at Van Devere Olds. That is who I bought mine from. You wont have to worry about bleeding the thing.