I thought this might be useful to somebody; My 95 has 300,000 miles on it, and last year it blew the seal out of the clutch slave cylinder. This year it happened again. The piston was coming too far out. The new one I bought this week had an internal snap ring that keep the piston in, and I could readily see that it wouldn't have enough travel to actually release the clutch.

I installed and verified this, and then I made a new pushrod about an inch longer. An inch is a lot in this case, that's about the travel there is. I googled this problem and found some discussion that there might have been a plastic "thing" on the pivot ball that might have fallen off.. It's possible the pressure plate fingers are bent, or the fork is bent. All I know is making a new pushrod was a lot easier than fixing either of those problems.

 

Or worn out clutch disk.

 

It's the other way round. I figured somebody would think that.

 

In addition to the plastic pivot point on the arm there are actually two different pivot pin lengths that will have a massive effect on arm travel.