Manual linkage install help

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Was this because the clutch geometry changed between rebuilds?
I'm not sure why it happened. I put everything back the same as it was with the exception of a new disc. How many thousandths of an inch thicker could a new disc be compared to a used one? I changed it out just because I had it all apart. But I lost my full travel range and it became a choice of full disengagement or proper free play- not both. I even used an adjustable fork pivot stud and that helped but not enough. So the easiest move was to shorten the upper part of the Z-bar to get more travel out of the lower rod. I had even tried lengthening the lower part of the Z-bar but had no room for that extra travel down there. It hit other stuff that could not be avoided. IMG_1032.JPG
 
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