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[another Allan]

So, going back to my first reply, the clutch plates swell under 'normal' use, which then causes drag and further swelling. The clutch 'pack' is therefore thicker than when cold, so you have excessive free-play in the cable. Simon's outer cover modification allows a little more clearance in the clutch 'pack' when pulling in the lever, due to no 'lost' motion. My replacement non-dog-legged clutch lever allows even more clearance in the clutch 'pack' so that when there is the normal level of swelling of the plates, there is still sufficient clearance to prevent drag which is caused by 'hyper-swelling' of the plates. So, the plates still free and there is only a little increase in free play at the lever. I also adjust the clutch cable so that when cold, there is barely discernible free play. The plates always swell when warm which increases free play anyway - Leon's experience bears this out. Whether it is the material of the clutch plates at fault, I don't know. I suspect that Enfield's metallurgical skills are somewhat lacking in this area! If Simon is having problems with 'belling' of the plates, I guess that this points to incorrect grade of steel, so the Surflex ones may resolve this. On the other hand, could severe overheating in use have 'softened' Simon's plates? My money is on the wrong grade of steel. .............It's strange that my 625 clutch has not had this problem. It will slip when provoked, but I plan to fit a 5-speed box and later clutch with Surflex plates, so that should be that! A Newby clutch is a (financial) bridge too far.
Summary, IMHO? Belled plates = wrong steel = fit better quality (Surflex?). Excessive free play developing in cable = swelling plates and nothing to do with the pushrod. A swelling pushrod will REDUCE play. (All of this is my opinion only!)