Question about Suzuki RM 125 Motorcycles

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Suzuki RM80 clutch will not disengage.

The clutch on my RM80 won't disengage. When I pull the clutch handle, it does not take the bike out of gear. So, when I attempt to shift from neutral to first, it just lurches forward and stalls.

Posted by Anonymous on

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Steve P

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  • Suzuki Master
  • 3,712 Answers

Hey Anon,
First, make sure the clutch is adjusted correctly..This video is a basic tutorial.. use it for a guide BUT DO the steps as I TELL YOU..
1. Loose the cable adjuster at the handle bar.. run the adjuster in - (give it as much slack as you can)
2. The clutch actuator lever on the engine case should be able to move about 8mm (.325") before it starts to disengage (gets hard to move)..
3. Adjust the cable at the bottom adjustment to take up any slack at this point.. ..you MIGHT/should be able to feel some (NOT FULL TENSION) clutch disengagement in the handle bar (clutch) lever at this point.. IF YOU CAN'T - tighten the cable at the bottom adjustment ONE round at a time until you can feel (a small amount) tension and have at least/about 12mm (.48") max. of play in the lever (BETWEEN THE LEVER AND THE MOUNT when YOU START TO FEEL TENSION... - NOW - in the clutch lever (handle bar).. when you can feel tension in the lever... >> you should start adjusting the lever to have (at least) approximately 1/8" - (3mm) of play (gap) between the lever and mount.. when you have this set correctly, the clutch adjustment question is eliminated. If the adjustment has not helped and you had to do A LOT of adjusting. you need to replace the clutch cable.. and do this adjustment process again. NOW adjustment is NOT part of your problem. If this fixes your problem GREAT!!
.. If not.. now.. we have to move internally..The next issue will be grooves worn into the arms of the clutch basket be the fiber clutch plate ears..(see picture) (the ones that keep the plates stationary when you shift to help disengage the clutch). Also check the actuator arm (see picture below) for wear..



. How to Adjust Clutch
Suzuki RM80 clutch will not disengage. - clutch adj-1yabyasfolpfscp5rjzzy1he-2-0.jpg

Suzuki RM80 clutch will not disengage. - clutchparts-1yabyasfolpfscp5rjzzy1he-2-5.jpgyabyasfolpfscp5rjzzy1he-2-5.jpg" alt="clutchparts-1yabyasfolpfscp5rjzzy1he-2-5.jpg" class="h_mi" />
Ok.. if you have gotten this far and everything seems good, reinstall AFTER YOU HAVE METICULOUSLY CLEANED THE BASKET!! The clutch should be working now.
Congrats!! If you need professional port work contact me..
Suzuki RM80 250 89 95

Posted on Jul 09, 2017

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Gregg Mahin

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  • Suzuki Master
  • 64,934 Answers

Hi, Anonymous for more information about your question and valuable "FREE" downloads that you will need please click on the blue links below. Good luck and have a wonderful day.
Clutch wont disengage
Clutch will not disengage fully
Suzuki RM85 Owner Service Manual
OEM parts for Suzuki
http://mybikemanuals.com/suzuki

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

Posted on Jul 09, 2017

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