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I’ve got a couple parts unlimited clutch cables for sale on eBay . $30 shipped for both. See listing below. https://www.ebay.com/itm/Parts-Unlimited-K28-2524-Yamaha-Xs650-Clutch-Cables-2-/232794225293

You can register them in Vermont and can live out of state. You do need a bill of sale from the last registrant though. You should be able to do it over the phone . They'll send you a Vermont transferable registration and a plate, then you can take that registration to your dmv to get a title...

64-72 Harley drum swap is another option. They're not the cheapest but you can still find a good deal. Basically all you need to make is axle spacers and a stay for the drum plate. If you want more info let me know.

16/19

It's been a while but I believe there's a barrel adjuster on the stock setup that wouldn't work. I used a rubber spacer on the threads of the cable fitting so it just sits in the housing. There's a little play with it not being threaded in but doesn't make any difference.

Couple pics.

I'm running it with stock bs34s. Should be able to use it on any single cable setup I would think.

http://www.monstercraftsman.com/7-8-throttle-assembly-with-vintage-style-grips/

The monster craftsman throttle is what I'm running. It's clean and it's pretty cheap. I can take a pic later if you want one.

Since you had the clutch apart and what you're describing it's probably out of adjustment.

Did you chamfer the edges of the hole before you put the new seal in? If not there's a chance the new seal was damaged upon installation. I agree with changing the bushing and going with the 1 piece rod. I was able to get the old 2pc out with a magnet when I did mine.

+1 on the agm Big Crank battery. I've had mine for 2 years with no issues on a hardtail, after multiple junk lead acid batteries.

I've done it a few times by myself. I built a table for the bike that's about 4ft tall, so lifting the engine and sliding it in isn't bad at all. As mentioned protecting the frame rails is a good idea. Never done the laying the engine/frame down technique but lots of people have done that too.

You said the battery is fairly new/just charged but have you tested its voltage with a volt meter? I've had brand new batteries shit out after properly filling and charging so it's something to check. Also as mentioned, ditch the stock fuse panel asap.

If you look under xsleos profile he has pics-maybe he'll chime in with specifics. http://www.xs650.com/media/albums/282/

What hardtail is it? With the wheel on its hard to measure but mines about 8" on a tc bros hardtail.

This is what I've always gone with.(1-2mm)

http://www.mcmaster.com/#98543a112/=shnkht