Sorry in advance for the long post but I want to give all the details.
Bought the bike used. Found that the prev owner had the clutch in a bind. When lever was pulled one side of clutch pack was releasing other side was not. Pulled apart cleaned and put back together all was well. Had motor problems , pulled motor rebuilt back together runs great. Put about 500 miles on it and while in Daytona for bike week clutch finger decided to go out. Was last day there so loaded up brought home.

Now comes the dilemma and this has been a problem from day one. Old clutch finger showed symptoms of constant load. I cannot get the clutch to adjust properly. I cannot get any freeplay at the lever and be able to disengage clutch. I have replaced the diaphragm spring, someone put a heavy duty Barnett spring in, I replaced with a screaming eagle. Replaced clutch pack, replaced inner hub ( original had the notorious crack), replaced cable, replaced clutch rod, adjuster and throw out bearing assembly, replaced clutch finger. Pretty much everything. I have adjusted the clutch pack per the sticky, I have the diaphragm spring perfectly flat. I did the unthinkable and took all the free play out of the cable to get the clutch to work. Well we all know what happens when you leave a load on that delicate little throw out bearing. Yup lasted about 3 miles and POw. So why can I not get my clutch to work properly. I have the service manual and have followed in in depth. Please help the weather in beautiful.

 

I also forgot to mention that the cable adjuster is maxed out .

 

Try setting the adjusting stud 1/2 turn out instead of 3/4 turn.

It looks like you have done everything correctly...

I had good luck with this type clutch on my `89 for over 100k, but it had the stock spring.

 

Can you describe what the stock spring looks like. I ordered what I thought was stock but it didn't look like what I had. Think the one they sent as stock has 8 notches in it as opposed to 12 on the screaming eagle . I have thought about switching them.

 

I just looked at one of my old teardown pics, the spring had more than 8 notches for sure (it is partially obscured in the pic).