I wonder if you have the dreaded "basket notches"? With engine running and no load conditions, the clutch could fully release and hitting the kill switch would leave it released BUT when stalling with clutch released the plates could sitting against the basket & not release when the lever is pulled.
Just a thought to check on. Good luck
__________________
Fred Overstreet
2010 EC250 SixDays
2004 GasGas EC300 -Sold to a good home
2006 GasGas EC250-Sold to a good home
2006 GasGas TXT 280 Pro 
|