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[Norm]

It has nothing to do with the cable, follow Franks advice and also check the rod to ensure it isn't starting to mushroom one of the ends because it has been overadjusted and spinning the rod constantly. A few thou worn off the end of the rod can play havoc with the adjustments

[Craig]

Yes As Norm & Frank Said...Just Re Read this at Work, "I Thought You Ment The Adjuster On the Cable End That Went Into The Outer Gear Box".SORRY..(I Recently Changed My Clutch Rods & a New Ball Bearing and They was 7mm Difference Between New & Old..Hope it Helps)..Good Hunting!

[Nick Name]

Many thanks I think your advice will get me there!

[Frank]

Just one more thought. The clutch pushrod / pad assembly should have a bearing washer on the end of it. If that has fallen off during assembly, or otherwise been ommitted, then the pushrod will need 3mm extra movement to engage with the pressure plate. Enough to use up the lock nut thread on the other side I would imagine. Our hosts modified clutch pad with needle roller bearing would replace this. You will need to take the clutch pressure plate and springs off to check this.

[Nick Name]

I haven't done the road test yet but yes the clutch hub nut was loose so many thanks for that tip, and all the other suggestions - everything's back together and seems to be working so hopefully that's one problem sorted!