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what kind of bike is it?i know how to adjust the 900-1000 but not sure which bike you have;)

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is there a little cover that goes on output shaft cover to adjust the slack in the bell crank looking piece under cover?if so normally youd back the jamb nut off and loosen the stud.then screw in the stud till you just start to feel resistance and tighten the jamb nut then move up to center of cable and adjust for about 1/4" of thread and do then adjust the rest at bar.sound about like what you did? goodluck,happy wrenching!

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if you are trying to get it out of the lever sometimes ive ha to back out the adjustment on everything then pull the lever off to get the cable off the lever.

You should have an adjustment section in the centre of the cable that you can tread all the way together that may give you enough slack to disengage the cable from the lever. Normally the centre adjuster is turned all the way in during assembly, and then out to give you that few mm of free play at the lever.

I think the above probaly has been tried by you already though. You can remove the trapezodial cover and turn out the nut as far as it will go, without forcing. This, with the centre adjuster shortened all the way may help. Just don't forget to readjust the plunger and locknut under the cover and your free play when your done.

Sounds like the cable has been installed OK at the countershaft sprocket cover... the spring goes INSIDE and don't forget the cotter pin in the clutch rod pivot mechanism to hold the end of the cable.

The cable should seat in a hole in that cover.

Next step is put about 1/4" between the switchgear adjuster and the grip. Then move the mid-cable adjusters towards each other... One may be a barrel type thing and the other a locknut. You may need two 10mm box wrenches or one 10mm and one 12mm depending on the cable manufacturer. This will give you MAX cable slack.

Adjust the clutch pivot adjust screw by loosening the 12mm locknut. Turn the screw all the way till it slightly tightens and then back it off about 1/2 turn. You may have to play with this adjustment AFTER the cable is adjusted. You can leave the locknut and cover off as you may have to road test. Put the locknut in your pocket if it can get lost.

Now, take the slack out of the cable at the two mid-adjust points by turning them away from each other. Once that is done, readjust the round adjuster up at the switchgear so you only have about 1/8" gap between adjuster and barrel thing.

Go for a short test ride... when you take off, the clutch should release where you feel comfortable. If you need to you can turn the adjust screw in or out JUST A TAD. Once you are happy, put that 12mm locknut back on and the cover as well...

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