I would like to know how you are adjusting your clutch operating assembly. You should have your cable adjusters slacked off, then screw in the clutch operating assy. adjuster stud till you just feel a slight resistance and then back off about 1/8-1/4 turn then lock down nut. Adjust cable at gear box front cover housing and then fine adjust on handlebar if you have an adjuster there. Make sure your cable is well lubed and is routed correctly so it doesn't bind. I would say the way it is working now it might not last long. If none of this works you may have to take your clutch apart and make sure all parts are correct. I think you mentioned in a post that you had to grind your clutch rods down a bit. I have worked on both 4 & 5 spd clutch assy.'s and never had to grind or mod a thing.
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