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"...Even with the cable adjusted out fully..."
Does that mean you tightened the cable all the way or loosened it all the way?
"... Could the fork be bent or something like that..."
Yes - somewhat common. Sometimes they develop a crack, hidden inside the boot, and then start to bend. They can act kind of "springy" such that the free play feels OK, but when you press on the pedal the fork just bends instead of disengaging the clutch. Then when you let off on the pedal the fork springs back to give the appearance of proper free play.
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