Here's the deal. I disassembled my bike for paint and some body modifications. One of the things was to add a fairing to do so I needed to re rout the clutch cable. To do this I Lengthened the cable at the cable adjuster and removed the cable from the handlebar and clutch lever.
After re routing the cable I replaced the cable into the clutch lever and handlebar. When I attempt to adjust the cable I cant get the clutch to engage(release plate would move about 1/16 to 1/8"). So I removed the clutch cover loosened the lock nut, backed the adjuster screw out, then turned clockwise it until I could feel pressure, then backed it off 1/2 turn and tightened the lock nut. NO CHANGE WITH CLUTCH.
Next I removed the clutch release cover. The ball and ramp, diaphragm spring, throwout bearing and thrust washer, push rod all appear to be fine. Reassembled everything and STILL NO CHANGE WITH THE CLUTCH. What am I missing.

Roach

 

Geez, that's hard to figure out without being there to help stare at it... My first thought is the clutch cable adjustment and make sure the cable ends are seated inside the adjuster ferrule. And since you've already checked inside the 'kicker' cover, I would suspect a bad cable.
That's all I can offer till I can think up something else.... Hopefully someone can chime in here and nail it down for ya!
Good luck,
jim

 

I would take a closer look at the adjuster you origanally slacked up. I did the same thing and had a problem getting it to seat.