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amber Posted on Aug 17, 2015
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Clutch in a 2001 suzuki bandit 1200 isnt disengaging

My boyfriend replace his clutch in his bike like 2 weeks ago. the clutch wasnt engaging all the way. he replaced the master cylinder. his bike did ok for a couple of days then. his clutch started slipping. he replaced the slave cylinder saturday. now it wont disengage now. please help. i was wondering could it be the pressure plate.

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Steve Luck

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  • Expert 203 Answers
  • Posted on Aug 17, 2015
 Steve Luck
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Is the clutch pushrod moving freely and not stuck in with grime? It is behind the slave.

Testimonial: "yes he has. i wondering could it be the pressure plate cause it to do that? before his clutch went out his bike was doing good now hes just runing into problems after problems and spending money on it. ugh it sucks. now he stumped about it. it will disengage while the bike is off so it will roll. but soon as he starts the bike it wants to take off but engine stalls wen it take off"

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I have bandit 1200 wont start in neutral with side stand down also no neutral light on dash. bike year 1999 please help

This could be the clutch switch:
1. Check the wires to make sure they are plugged firmly into the switch.
2. Use a voltmeter to check that resistance through the switch goes to zero when the clutch handle is pulled in.

If you have replaced the clutch switch with a fuse....check that the fuse is good and the blades are not corroded.
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We rebult clutch and now the clutch does not engage. We have bleed the lines and it still does not engage. Any suggestions will be appreciated.

I had a similar problem and found that when I put the clutch back in, it wasnt quite seated correctly, i,e one of the bolts that go onto the springs was catching on the basket. This gave the same symptoms as you have. Also, is the cluch slave cylinder operating correctly? Might be worth removing it and checking the clutch is pushing the slave cylinder plunger forward.
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Not enough play between clutch engagement. Pull lever all in, put into gear and clutch almost immediately engages as you let the lever out.

check your master cylinder fluid level you have air in the line, you need to bleed out the air bubbles.
remove the master cylinder cap make sure yo uhave enough brake fluid pump the lever watch for fine bubbles keep doing it until you feel the resistance build up and the air bubbles are gone ad fluid to proper level replace the cap.
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'Sticky' gearbox on 2004, 1200 Bandit

Have had the smaller brother of this bike, here is what I found, try using 10W40 full synthetic oil, make sure the clutch is adjusted exactly right, if that doesn't help the engagement dogs are worn and u need an overhaul, which isn't that hard, about 10 hours work and $200 in parts.
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Hello I have a 2001 Suzuki bandit 1200. The problem is when I depress the starter switch. I hear the normal spinning of something below near the top of the engine. but the motorcycle wont start. 2...

I had the same thing happen. It's a problem with the starter clutch and how it's attached . A primary bolt is loose. Be sure to have your mechanic use some locktite or really wrench it on there tight--my guy fixed it and then the same thing happened again 10 mos later. But it hasn't happened again in the several years since then. Good luck.
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Clutch stack height

did you replace both sets of plates or just frictions? did you use oem or barnett springs? do you have proper lever free play? is your baskets fingers worn or grooved?
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