The suspense of waiting for a solution is killing me. I have read and reread your post. I cannot confirm whether the projection of the throwout bearing beyond the rear of the transmission is correct or the problem, but try adjusting the levers and cable by this procedure.
1. Set the lower clutch cable exposed spec (75mm) on lever #7 in the parts diagram with the knurled adjuster at the hand lever.
Make sure the lower end of the clutch cable outer sheathing metal end is properly seated in the correct position. The bolt on #7 lever with the 10mm head (#10), at the rear of the throw out bearing, should be loosened so as to not to be making contact with the throw out bearing. Clutch is fully engaged.
2. Screw bolt #10 in by hand until it just touches the throw out bearing and hold with a 10mm box end wrench while securing the 13mm lock nut.
Back the 13mm locknut back far enough back before screwing #10 in by hand so that your are sure that it is the bolt that is making contact with the throwout bearing. So far the clutch is fully engaged and there is no slack between the handlebar hand lever and the forward end of the clutch rod at the pressure plate.
3. Set the cable freeplay at the handlebar lever to spec. (4mm?)
Screw the knurled adjuster IN so that there is Freeplay in the cable before it disengages the clutch assembly. It is measured at the first place that opens when you pull the lever. You can almost do this by feel and not sight. This slack ensures that the whole clutch assembly is fully engaged and not preloaded or partially disengaged when the lever is out.
Don't forget to set the knurled locknut on the cable adjuster.
Hope this helped. Whatever the solution turns out to be, please let us know.
Charlie
1. Set the lower clutch cable exposed spec (75mm) on lever #7 in the parts diagram with the knurled adjuster at the hand lever.
Make sure the lower end of the clutch cable outer sheathing metal end is properly seated in the correct position. The bolt on #7 lever with the 10mm head (#10), at the rear of the throw out bearing, should be loosened so as to not to be making contact with the throw out bearing. Clutch is fully engaged.
2. Screw bolt #10 in by hand until it just touches the throw out bearing and hold with a 10mm box end wrench while securing the 13mm lock nut.
Back the 13mm locknut back far enough back before screwing #10 in by hand so that your are sure that it is the bolt that is making contact with the throwout bearing. So far the clutch is fully engaged and there is no slack between the handlebar hand lever and the forward end of the clutch rod at the pressure plate.
3. Set the cable freeplay at the handlebar lever to spec. (4mm?)
Screw the knurled adjuster IN so that there is Freeplay in the cable before it disengages the clutch assembly. It is measured at the first place that opens when you pull the lever. You can almost do this by feel and not sight. This slack ensures that the whole clutch assembly is fully engaged and not preloaded or partially disengaged when the lever is out.
Don't forget to set the knurled locknut on the cable adjuster.
Hope this helped. Whatever the solution turns out to be, please let us know.
Charlie