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 only moves about 1/16 to 1/8"). So I removed the clutch cover loosened the lock nut, backed the adjuster screw out, then turned it clockwise 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

 

Hi Roach, fellow 1990 FLHS here. The problem is with your cable. Either the rerouting has messed it in some way, or it is not sitting correctly at one of the places it mates, something probably really simple. You could do with a buddy who can take a look over it with you, to see if an extra pair of eyes can spot the problem.