Correct, all new cable assembly. I bought the bike in non-working condition, so i can't speak to how the foot clutch setup performed before that. I did have the tranny looked at by a shop though, and had a new clutch hub installed. They didn't find anything else wrong on the clutch side.

The tranny pushrod has a flat side that doesn't seem to lock in anywhere, is it supposed to? Trying to eliminate possibilities.

I can seriously back the cable aduster completely off the threads with NO change in tension. This is AFTER I adjust the clutch. Probably a user error but i haven't found it yet.

 

I think this is where your error is.

 

Ranger, can you shine more light on this? I did the clutch adjustment per spec several times: loosened the lock nut, found the point of tension with an allan key, then back off 1/4 turn. Tried it again at 1/2 turn. Then just for the hell of it tried it at the point of tension to see if i could get some feel in the clutch lever.

I did this every tine with all full slack in the clutch cable, then backed out the adjuster nut (after clutch adjustment) hoping it would take up cable slack. Thanks

 

Chris this is the only thing I can think of at this point.
On my clutch hub there is a point when I'm turning in the clutch adjuster that it binds up for a second giving a false feeling that it is seated, I have to turn past that point to really seat the adjuster.
That maybe what you are experiencing.

 

In your picture it looks like your turned in to far.
I did this too.
loosen the cable, back out the center bolt then slowly tighten it until the allen key will "hang" and not fall clockwise under it's own weight, that's the tension spot. then back off 1/2-3/4s of a turn.

 

This is probable your problem. if you do indead have the proper cable. That fine thread nut is very easy to over-tighten and burr the threads. Extend the cable out at the lever so you can get some movement at the clutch. Now while squeezing the lever and releasing, turn the adjuster in on the clutch till it takes all play and then in two or three more turns. That is how you deburr it. However, when I look at your picture with your adjuster all the way in, it appears something else is wrong.
Maybe the cable is not correct with the steel cable being too long for the sheath. The adjuster screw has been modified or the push rod is bent. Remove the snap ring and pull out the adjuster and pushrod and check the ends. Could be your throw out bearing?

However, I have see the same thing over and over on here and it's simpley burrs on the clutch adjuster.
I know the instructions also say loosen the cable all the way before adjusting. This 90% of the time makes so much length, you cannot tell what you are doing. Only lengthen cable for a little free play. If you have a little, that's enough. Then deburr and set.

 

I did this one time and could not get my clutch to produce any resistance racked my head over it. Turns out my dog nudged the clutch pushrod under my garage shelf...........

 

Your clutch is adjusted way too far in for one thing,.

 

I thought so too at first glance then I realized he is not using the OEM locknut.
He is using a standard nut which is a bit thicker than the OEM locknut.

 

Progress report or findings?????