*edit, didnt realize this was a ressurection from the dead when I posted this.

It sounds like you dont have enough cylinder travel and your clutch disc is still in the friction zone while your shifting.

The pedal adjustment How to, and even the service manual leave out a very important part of adjusting the Evo's Hydraulic self adjusting clutch assembly. The pedal adjustment arm has a hole inside of the resivior that allows 'additional' fluid to enter the clutch line and slave cylinder to offset clutch wear. If you make your adjustment rod too long or this will close off the hole and inhibit additional fluid from entering the line making the system NON self adjusting.

What you want to achieve is maximum allowable rod travel without closing off the ability for it to self adjust. The way you check to see if you've closed off the hole is to check at the slave cylinder. You should be able to compress the slave cylinder with your hand which will cause fluid to be pushed back into the resivior. If the rod is too long the slave cylinder will not compress because the hole is blocked which allows fuid to travel. Also, you should bleed the slave cylinder while your at it. I did this procedure this weekend and my Exedy Stg1 actually feels pretty good and doesnt lock out at all anymore.

Proper Clutch Pedal Adjustment video from Jack's Transmissions.
http://www.youtube.com/watch?v=vYJxQyjIhUw

 

bump thread for easy find... will need this info for after work... cant see the Vid.