iv tryed 2 clutch cables and both seem to be about half a centimeter too long.  my worm cover is a little different as it only covers half the drive gear.  im worried is it my cover thats the issue?  i made a little washer type spacer that slid onto my cable where the other spacer thing is.  its not ideal though because now the cable kinda scraps the cover.  anyone else have hell with the ebay dt1 cables?  i guess im gonna have to shorten cable another way in long run.  thanks

Have you tried a cable from KDI repros? They make quality products for these bikes.

the ebay ones are kdi. my cover kinda dips down where the cable hole is so maybe its my cover. ill try and take a pic. i want to learn to solder my own but honestly the motion pro solder brass ones are expensive. i got some screw up kind coming. know if you can you desolder nipples on the cable and reuse them? know if you can solder the screw up nonsolder kind for extra strength?

Many KDI cables have been installed so trying to shorten one sounds like it could be a "band aid" fix to a problem with the plastic worm gear slipping on the shaft that might leave you stranded someday soon?

It's also possible the gear is engaged a tooth off?

Also are you sure you didn't lose the ball for the clutch pushrod when you were messing with the clutch?  Pretty common thing to happen.  

#13 in the diagram. www.partzilla.com/catalog/yamaha/motorcycle/1969/dt1b/clutch

99 percent sure ball is in there. thx i got a brass worm gear to install but when i had it apart installing it was over my head so i think plastic one still works fine althought dont know why they put something so cheap in there. see how my cover is not flush at top when screwed up tight? and then theres like a little dip in cover where clutch cable goes threw. i put a little spacer on end of cable you can see in pics. its only like half a centimeter. was there something extra on my cover like a gasket or something metal where the clutch cable hole is that would create a half centimeter?
imgur.com/a/JGHIhKs

An observation:
Your chain cover appears to have slipped under the serial number plate area.  Its hard to tell as my own bike has a cutout there.  The red line in photo is the point of contact for the cover and L case.  Of course, this would make you use less adj, so that doesn't make sense I guess. 

I would also wonder if the clutch pressure plate is pushing L and your cover is twisting R as actually there is no supporting mount on the rear of the cover.


See if this helps.  As I look closer at my own cover, I find the prev owner put a spacer at the end of the cable.   LOL, works for me.  I guess I just found out!
Misery loves company.