Hey there everyone i am a proud owner of a 2001 suzuki savage, im having some trouble with it. You see, i just replaced the clutch cam release after it broke on me shortly after buying the bike, i didnt even ride the bike for more than 200 miles before it broke again.  

I have checked the arm by the case and it sits between the marks correctly i havent adjusted the cable and it seems to be fine and have the right amount of freeplay (something like 3mm or so by the handle?)

Am i doing something wrong? The first time i replaced the side cover the feel i got from the clutch lever was very nice i could pull it in with just two fingers but i used the wrong gasket maker and leaked oil all over so was forced to pull it again and do it right, the last time i installed the side cover the clutch lever was hard again but i didnt bother to remove it again as i was worried the seal i was making with the gasket maker on the sidecover wouldnt be too great if i did, is there a certain way for the spring to sit in there or something?
The way i see it is something or somethings in the system are not up to mark and its placing a great stress on that part so it continues to break as it is made from some weaker type of metal (so that it breaks first).

Help guys this is a real bummer i just wanna ride!

Why are you using "gasket maker" on the clutch cover?  The factory didn't use it, and I don't use it and mine clutch cover doesn't leak.

Get a new gasket if the old one is hard or torn.  You can re-use the gasket several times......I have had my clutch cover off 2-3 times with the same gasket.

the last time i installed the side cover the clutch lever was hard again

Pull the side cover. Pull the rod out & Look At it carefully. Look for any sign of a mark on one side.
Something in the clutch pack is wrong or something is dragging on the rod. How hard it is to pull the clutch in 200 miles shouldnt change,Its not between the clutch lever & that throwout cam, or the cable would be a mess. If it got harder to pull the clutch AND the same part broke,, something is up in the clutch pack or something is in that hole the rod sits in,


the last time i installed the side cover the clutch lever was hard again

Or, am I r4eading this wrong? Are you saying it was hard after you put it back together, but not before?

The lever was hard to pull when i first bought the bike, after i installed the new rocker arm for the first time it worked really easily, but i was forced to pull the side cover yet another time to fix the seal and then thats when it became hard again.
I was looking at the rod and it looked fine, your right it shouldnt change in 200 miles i think maybe it gets harder to pull once the rocker arm creates a crack? because it also get harder to get it into gear sometimes right before it breaks.
It might be from snapping the lever back like verslagen said but i only do that when im riding hard and trying to shift fast and i dont think the way i do it is abusing it in a way that it will break?

When it was hard to pull in, i dont think it would pop back quickly but it did feel like at times it was just a bit slow pulling in the lever again but that could have been my hand getting tired?
It might help if i mention that the clutch does slip under hard acceleration. and the bike has almost 20k miles on it.

Maybe I am overstressing the part by bottoming out the clutch rod. I can also imagine how it fitting loose over the shaft could cause it to break too, is it supposed to wiggle a bit if anyone can recall or is it not supposed to have any play?

Sounds like it's bottoming out to me.

This is the timeline I read:

Hard to pull
-
took apart/reassembled
-
Easy to pull
-
took apart/reassembled
-
Hard to pull

Is that correct or does it vary while you're riding it?