How does a poorly adjusted cable lead to a burned-out clutch, even for “hard” riders?

Answer: When a clutch cable has zero free play, it’s no different than riding with the clutch lever slightly pulled in, causing clutch slippage, overheating and premature wear of clutch plates. If a clutch cable is too loose, when you pull in the clutch to find neutral or shift gears, the clutch is not disengaging as much as it should causing hard shifting and difficulty finding neutral. Set the clutch cable free play at 5mm and if this does not “fit your hand” size buy adjustable levers.