Clutch would never engage...any gear, any adjustment on the worm gear or cable...just wouldn't go.  Changed the oil (had synth in it) with no luck.  Changed again with some case flush solvent with no luck.  Broke down and pulled the clutch, but there's nothing obviously wrong with it.  Is there something I should look for?

awww...come on.  lots of ppl here have SV650's...

Clutch wont engage ... as in put it in gear and let it out and it dont get power to the wheels ?
Do the crank to outer basket teeth look good ? ... maybe its not going from crank ... Bad splines on the crank ?
Cool.
Buddha.

nah I checked the plates out in good light and they were shot...total thickness of the plates + contact surface was like .090".  So thin in some places that I couldn't touch it with my fingers because it would rub off.  I rearranged the plate order and put it back in and got him some grip but he's gonna have to replace the clutch.