Question about 2004 kawasaki ZZR 1200

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MY CLUTCH LEAVER STUCK OPEN AFTER BEING OUT IN THE RAIN FOR A CPL OF WEEKS, I SPRAYED WD40 ON IT AND IT THEN PULLED IN OK....BUT WHEN I WENT INTO GEAR NOTHING HAPPENS WHEN I RELEASE THE CLUTCH LEAVER AGAIN. I WOULD BE GRATEFUL FOR ANY SUGGESTIONS AS TO WHY AND HOW TO FIX

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Just have to keep working it to free it up... spray more from the other end of the cable too.

Posted on Feb 24, 2009

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1 Answer

Clutch plates stuck


1- Is it in neutral?
2- check is the clutch leaver in the clutch housing cover is not stuck.

When in neutral start the engine, let it run until it is a bit warm ( check the gage ). Then the gearbox oil should become a bit warm too. This will make the clutch plates expand a bit and pop loose.

Mar 29, 2012 | 1982 Honda GL 1100 Gold Wing

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I have a 2002 honda vt600c bought it from a guy that I watched ride it but after it sat over winter the clutch doesnt seem to work ..shift into 1st and it kills bike. any ajustments I can make or do


Sounds like the clutch plates may be stuck together. Happened to me after a long trip in the rain and bike sat for a few weeks after that. Had to take the cluch discs out and clean them

Mar 25, 2012 | 2004 Honda VT 600 C Shadow

1 Answer

I just started my 2006 suzuki gsxr 600 for the first time since fall and it starts fine in neutral but as soon as i put it in gear it cuts off. The kickstand is up


Sounds like your clutch is stuck on [not disengaging when you pull the leaver]This can happen over a long storage-no use period.To fix put the bike in 3rd gear and start the engine with the clutch lever pressed[caution the bike will want to surge forward so keep your foot on the brake]Make shure to have the engine up to normal running temperature before you try this fix.the engine firing along with the brake pulled will release the sticking clutch plates.This will work!!!

Mar 08, 2010 | 2006 Suzuki GSX-R 600

1 Answer

Gears are stuck


chances are the gear selecter shaft was pushed in when it went over and possibly jammed the selector fork remove the clutch cover and have a look you might get away with just knocking it back into place if nothings been damaged

Dec 17, 2009 | 1991 Honda NT 400

1 Answer

74 honda TL125 with a free play feel in the clutch leaver


On most bikes, there is a rod going down the center of the clutch. The lever on the case pushes this rod in when you squeeze the lever on the handlebar. If the rod going through the clutch will not move, the clutch will not release. It doesn't move very much, maybe a few millimeters. If you cannot remove the rod[you may have to use a magnet to pull it out] then the rod is bent. This could have happened if you assembled the new clutch incorrectly. If the sequence during reassembly was wrong, the disks were jammed. When you squeezed the clutch lever, something had to give. The clutch rod.

Sep 21, 2009 | 2008 Buell Blast

1 Answer

Push in clutch lever play even with new cable on my 74 TL125


It still sounds like that roller ball is missing. Do you have a manual to check for exact location? Yamahas have them on the casing side but not sure about Hondas. It is REALLY easy to drop out without being seen.

Parts in that casing do not usuall "weld" themselves together unless someone has really been abusting the clutch. Could be the clutch spring has lost some tension but no way to tell without comparing it with a new one. If you had a manual or even a friendly dealer you could find out proper specs. for the spring and then measure yours.

Don't just start replacing parts without verifying they have failed. It can just get expensive and not solve anything.

If you have a digital camera, take a picture of the assembly you believe to be seized together and email me at robertlanglois6@sympatico.ca
I will see what I can figure out.

How many hours / km on the bike? Clutch plates may be kaput but you don't mention clutch slipping?

Don't cut the cable yet. If you do, just trim it to about mid adjustment. It is easy to cut a bit more than cut too short! Either way, cutting is a bodge job. Best to find root cause and fix it.

Send me pictures if you can.
Rob

Sep 21, 2009 | 2008 Buell Blast

2 Answers

Wont keep running


Maybe some water in an electrical plug. Remove the tank and dry it all out with compressed air or WD40. Work around the coils and other wiring. Also where the wires come out of the engine case.

Jun 15, 2009 | 1991 Suzuki GSF 400 Bandit

1 Answer

Yamaha Virago XV125 2002 Clutch not releasing when leaver pulled


You can download a free manual at carlsalter.com
good Luck to you friend....Tim

May 13, 2009 | 2000 Yamaha XV 125 - S

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