Just completed a carburetor rebuild. Biked started right up on 1st try. Pulled the clutch lever in to put her in 1st gear, lever would only engage about 3/4 of the way fully in. It felt like something was blocking the lever? Checked hose and lever everything seems fine. Any suggestions? Air in the system? Master cylinder spring/piston? Bike did engage 1st gear no problem a bit hard to shift back to neutral. Any suggestions?
Do you mean to say, you didn't feel the pressure build enough to disengage the clutch until the lever was pulled that far? If that's what you mean, then you have air in the system, very possibly at the banjo fitting at the master cylinder. Flush and bleed the system (should be done every year or two, anyway), but have the stand on a block that holds the bike near level, and turn the bars to the right, so the banjo is lower than the rest of the MC. After bleeding, pull the lever in slowly (count of 10), hold a few seconds, then let it snap back; this will force air in the banjo back into the MC, where is will be released into the reservoir. Repeat the slow pull, hold, and snap back a few times, to get most of the air out. You can do with with the cap on, so it doesn't splash fluid where it can harm paint.
