Question about 2004 Suzuki GSF 1200 Bandit S

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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.

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If the bazzz7071's solution doesn't work, here you go:
Check if the slave cylinder's cover (part No.35 on this schematic: Clutch schematic Suzuki Gsf1200 Bandit 2001 2005 usa) is deformed and worn dye to contact with the drive chain.
If yes, then buy a new (and longer) push rod from DL100 Vstrom (part No.21 here: Clutch schematic Suzuki Dl1000 usa) and cut it so as to be 8mm longer than your original one. I had the same problem and my mechanic did that for me, after having inspected everything else. There's still a little mystery about the cause, but everything's working fine now.

Posted on Jan 27, 2014

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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.

Posted on May 11, 2010

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Posted on Jan 02, 2017

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You may want to make sure the clutch cable is properly adjusted. At the clutch lever on the handlebars, pull back the rubber cover over the end of the cable where it goes into the lever. You'll find a round lock wheel that you tighten to prevent the clutch cable adjustment from moving. Loosen that wheel then you can turn the clutch cable adjustment in or out to adjust the clutch engagement and take up. For those bikes, you want to adjust it so that there is a small amount of slack in the clutch lever. Look at the "crack" where the lever pivots when you pull on it. Adjust the clutch cable by turning that adjustment in or out until you have just barely enough opening to slip a nickel edge into the very outside of that "crack" when you apply very, very light pressure to the clutch lever (just enough pressure to take the slack out of the lever). Tighten the lock wheel back into place and try it now. Also, make sure you are using a good, FIRM foot pressure to engage each gear. If you don't engage firmly enough or the adjustment is out, then it will pop out of gear. You notice it more on the lower gears because the lower gears allow the engine to send more torque thru the clutch, thereby providing more force to make it pop out of gear.

If this doesn't help, then take it to a shop to see if it's simple worn clutch disks (easy to replace on this bike) or if the gears have worn teeth in the transmission.

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1998 Suzuki rm 125. Changed clutch lever and when pulled in its not engaging tried to adjust cable in all ways 1/4in play still nothing someone said to pull lever and duct tape it overnight maybe will...


I am sure it's a wet clutch. Pop your bike in neutural. Remove your clutch crank case cover and, using a screwdriver, separate the plates manually. Put the tip of your screwdriver between the edge of the clutch plates and turn the screwdriver. It will break the seal of your plates and spacers. Put it all together again. Do a fluid flush and refill your oil to recommended levels. Get the bike running again and give it a go. Should be fine. Good luck!

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Does it lurch forward a little? If so, First thing to check is the cable adjustment. As you pull on the clutch lever, you should be able to feel a little free play before the lever actually starts pulling the cable. You should have approximatley an 1/8 inch gap between the lever and the perch when lever engages the clutch.

If it's not the clutch dragging, check for a faulty kickstand switch.

Jun 10, 2010 | 1997 Yamaha Xv 250 Virago S

1 Answer

Started bike, pulled clutch lever, put bike in 1st gear, let out on clutch and nothing happened. clutch lever moves freely with no tension at all. when i put the kickstand down it shuts off like its...


The clutch lever should have some tension, so could be a problem with the hydraulic actuator stuck, or a failure of the clutch. try bleeding the clutch, or pull the clutch cover off and see if the pressure plate moves

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1 Answer

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Assuming the clutch handle on the handlebar is adjusted properly, only three things will cause the problem.
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  • Worn clutch lever (at gearbox). Lever is not moving the pusher far enough to fully disengage the clutch. A new lever would be needed.
  • Synthetic lubricant ( or oils with "special" additives), was put in gearbox. 10w40 motor oil should be used in the gearbox. Synthetics can swell the cork on the friction plates causing the clutch to drag. New friction plates will fix the problem.
The current amount of clutch drag is not enough to harness the power of an engine rev. That is why the clutch seems okay at higher revs. Please rate my answer. Thanks.

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1 Answer

I have a suzuki rm 125 1994 model when i pull the clutch lever in to put it in gear the clutch doesnt work t jst crunches into gear


Adjust the clutch cable to allow about 1/4" free play at the end of the clutch handle. Don't put the bike in gear until the rpms are near idle speed. The clutch is working fine if the bike does not lurch forward when going into gear at idle speed. Dirty, gritty oil in the gearbox can make the clutch grab. Consider changing oil if grabbing is the problem. The "crunch" you hear is the slider gear engaging into the driven gear. The higher the engine speed when being put into gear the louder the crunch. The slider gear engaging "dogs" can break. Crunching into gear is hard on the gears.

Post a comment to let me know how you come out on this.

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1 Answer

Clutch pulling


Your clutch is not fully disengaging.Adjust the cable at the lever until you have plenty of free play.Then adjust the cable at the motor until you have full engagement then readjust lever to 3/8 in play.Fine tune at the motor.It may take a few trys but you can get it.

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