Question about 2004 KTM SX 450 racing

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After installing new fiber and steel plates (seven fiber and eight steel). start motor, pull clutch lever in, engage first gear and release clutch lever. motorcycle does not move.

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Did you adjust the clutch cable? Have you replaced the springs in the clutch baskit with new one?

Posted on Sep 29, 2009

  • Darnell Sanford
    Darnell Sanford Jun 01, 2017

    No but i was was thinking 6th that



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How do i get the clutch out of a kawasaki vulcan 800 2003 model with out taking off motor

You dont have to remove the complete engine to replace the clutch !
All you do is remove the clutch cover with about 10 bolts securing it , might have to remove the foot peg and brake lever also !
Once cover is off then you will see the clutch assy , remove the end cover with about 6 bolts and then slide out the clutch plates KEEPING THEM IN ORDER !
Put your new clutch plates in a bowl of engine oil for an hour to soak , then check each metal plate for wear unless you are replacing them as well ! If you find they are a blue colour then lightly clean them with emery cloth ( abraisive paper for metal ) wipe clean and place new fiber coated plates in place of old worn ones sliding them back in order they came out ! Ive not got any torque settings but you can find them on the internet for the end cover and side cover , then replace the side cover etc !
Try the clutch , might have to adjust cable or if hydrolic then bleed by undoing the bleed nipple which is on the slave cylinder on the side of engine , undo it and pull lever in and hold it , tighten nipple , release lever and do this 2 or 3 times ! MAKE SURE THE CYLINDER ON THE CLUTCH LEVER IS FULL BEFORE YOU START !! If a cable then adjust off the adjustment on the hand lever leaving about 5mil slack , pull lever several times then re adjust cable till 3mil clearence on lever and try again ! Start engine and select 1st gear and carefully take for a ride changing gears , might have to adjust again but now should be ready to go and play !

Feb 20, 2015 | kawasaki Motorcycles

2 Answers

Nutural is very hard to find on my harley 1999 flhtcui

The guy talking about the kind of oil to put in your Harley is brain dead. Dont listen to him an ruin your bike. Best thing to do is call a Harley dealership an talk to them about the kind of oil to use. Im not going to give you my two cents worth but dont ruin your Harley listing to that dummy he knos nothing. Never put car oil in a HARLEY

Aug 27, 2012 | Motorcycles

1 Answer

I can kick start my 1979 rm80 suzuki but when I go to shift gears it kicks out and stops running what could be wrong with it?

Hey Michelle,,
This is something that will have to be looked into.. Sounds like the clutch may not be working.. it won't engage/disengage..(the clutch plates are stuck together - a common thing when older bikes sit for a while!!).. this will require the right side cover to be removed, the clutch cover plate removed, the clutch plates(fiber and metal) to be removed, then cleaned, oiled and everything re-installed in reverse order..with a new side cover gasket..

You MIGHT be able to put the bike in gear.. then try to push it (engine not running) with the clutch lever pulled in and get the clutch plates to break loose (seen this work a couple times)..
You SHOULD be able to push the bike(engine not running) in gear with the clutch lever pulled in!!!

Please rate as helpful.. thanks!

Suzuki RM50 RM60 RM80 RM100 RM125 RM250 RM370 RM400 Repair Manual 1975 1981

Sep 03, 2017 | Motorcycles

1 Answer

Hello. I have a 94 Suz Intruder 1400 and i just did new fibers and metals on the clutch and now when i sqeeze the clutch lever it is really hard to pull and when i put it in gear the bike stalls instantly....

Is it possible you have to many steel plates, have you by any chance put a metal plate up against the inner basket?a fibre plate should go up against this

Jul 27, 2011 | Suzuki VS 1400 Intruder Motorcycles

2 Answers

2 months ago i bought a second hand honda cb seven fifty f2 93 model the previous owner said he had only just put a new clutch in it but now when i start it up (i always leave it to warm up for a few...

It is possible that some of the clutch plates are stuck together. When you put in new clutch plates you are supposed to soak them in oil before installing them. If they were put in dry it would cause this kind of issue. All you can do is take the clutch apart and inspect them. Coat them with oil and put them back together. On most Honda's to put the cycle in first gear you have to pull the clutch lever all the way to the handle bar. After that you can shift the bike by feathering the clutch or by only pulling the lever approximately half way. Be sure you are fully engaging the clutch when you shift the motorcycle into first gear.

Oct 05, 2010 | 1992 Honda CB 750F2 Seven Fifty

2 Answers

1987 kx125 clutch wont engage

push rod bent ? too short ?

Aug 06, 2009 | 2003 kawasaki KX 125

2 Answers

Bike stays in gear with clutch in

You are saying that with the clutch lever pulled in the bike still wants to go forward. Generally that is caused by dirty, gritty oil in the gearbox. Go ahead and change the oil. 10w40 motor oil is what you want. I think that will fix the problem assuming the clutch plates were installed properly. The first plate installed and the last plate installed should be a fiber friction plate, 8 plates total. A metal pressure plate goes between each fiber plate, 7 plates total.

Be sure the lever assembly arm is installed so that it gets full movement of the clutch cable. If the full range of movement is not present then full disengagement of the clutch is not going to happen.

cape cod bob did you a good service in the manual referral. Be sure to say thanks.

Apr 16, 2009 | 2003 Yamaha YZ 125

1 Answer

I have a93 rm 250 clutch not engaging

I am going to stick my neck out here and hope I can help.
The springs are not at all likely to be the problem. Any chance the cable is hanging up and not releasing fully? Disconnect the cable at the gearbox, put the bike in gear with the motor not running and see if the motor puts a major drag on pushing the bike. If pushing the bike makes the wheel lock up or the engine turn over it tends to say the cable is bad.

It could be you were given the wrong hub. Compare the old hub to the new one. Do the various measurements match? Contact the dealers parts department and ask how many fiber and how many steel clutch plates are in your clutch. Did your 9 year old son play with a funny looking frisbie and leave it in the back yard?
Ask what plate goes into the clutch hub first > Fiber or steel? Did you install the plates that way? Did the outer clutch cap go on properly and rest against the outer plate? Do any of the fiber disks have a gap wider than the other disks?

Food for thought. I hope this helps.
Please rate this answer. Thanks!

Mar 30, 2009 | 2003 Suzuki RM 250

1 Answer

Clutch not working

it may just be the fibers sticking. If the bike has been sitting for a while the fibers will dry out and stick. I would remove all of them, and while keeping them in order dip them into some clean oil and replace them one by one. Be sure to inspect all of them for damage or excessive ware. Good luck.

Mar 26, 2009 | 1972 Yamaha XS2

1 Answer

I have an rm125 and wen at full revs the bike begins 2 slip but if i use half revs its fine what could be the problem

If you mean the clutch begins to slip after half revs then chances are that the fiber clutch plates are worn. I suggest you get a set of fiber plates and install. Pull the right engine cover and remove the clutch end cap. Note the sequence of plates as you remove them. You will have fiber plates and steel plates. Is the first plate removed fiber or steel? If the first plate removed is fiber then the next is steel, then fiber, then steel, and so on. Install the new plates in the same fashion. So if you started with a fiber plate you need to end up with a fiber plate when the install is done.

Pleas rate this solution. Thanks!

Mar 26, 2009 | 2003 Suzuki VL 800 Volusia

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