Tomorrow, if I have time, I will probably have to remove the left side cover and inspect the worm gears... I've been kind of rough on them. I took the bike for a short little ride this evening in order to do two things. 1. get a spark plug reading, 2. see if that loosens up the clutch. It didn't loosen the clutch at all... Hopefully all is good with those gears. In the future, I will refrain from rough-housing them. And yes, it is a VERY tough pull... My carpenter brother-in-law couldn't seem to pull it all the way in enough to engage the clutch unless he used two hands... I was probably too rough...Certainly an unusual problem. If the lever pull is hard for you - a bricklayer - most of us couldn't use it. The assembly appears correct in the recent pics and video. You appear to get about the right amount of movement without the pressure plate. You're right about over-tightening the worm adjuster - it'll break.
Have you removed the pushrods and checked them for damage and also check the bushing for binding? Unusual step, but unusual type of problem.
They honestly looked really good in my previous inspections, however, I have not 'fully' removed the long pushrod yet. I've only pulled it out to what I would guess as 90%. I will fully remove it and inspect it as long as 5twins cable oil concern isn't the fix. Also, which bushing are you referencing? I wouldn't mind inspecting it either way.
Thanks for your advice/help.