91 SUZUKI RM 125 CLUTCH PROBLEM

Are you using the correct 10W40W wet clutch motorcycle oil? It has special friction modifiers in it for this clutch drag issue.

You may simply just need to adjust your clutch cable. Make sure it feels like your pulling on something, there should be some resistance. Since you'll be adjusting it while the plates are cold you need to leave some free play in the lever or when your clutch pack gets hot it will start slipping and you'll end up with a smoked clutch. What I mean is grab the lever and pull it in until you start feeling resistance and then adjust it our until there is maybe a quarter inch of free play. Hope it helps. If its not that then you've got some internal problems with your plates and fibers not separating correctly.

84 rm suzuki 125. when i push the clutch in it stays in and dont engage

Clutch dragging / slipping? you need to have free play in the cable the lever should not be tight up against lever holder there should be a loose gap.

Have you recently had the engine case apart? [even if not], ..check your rubber O-rings [seals]. These o-rings, located inbetween the clutch case cover and the motor itself,...if damaged, allow coolant to seep into the oil.

What type oil in your crankcase? Wet clutches go on strike with wrong oil. Engine oil is a no no.

The clutch springs are not the problem. Check to see if all parts were installed as shown below. The clutch plates alternate Fiber/steel/fiber/steel, starting and ending with a fiber. Be sure the teeth on the clutch rack are pointing to the rear.

A “very helpful” rating for this answer? Thanks!

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.

1) Can you push the bike while it's in gear with the clutch pulled in? [If so, clutch is disengaging OK]

2) If not, check when you pull in the clutch lever that it pulls all the way through to the actual clutch [If not, replace broken clutch cable]

3) If so, clutch is binding. Either fix it properly by stripping the clutch.. or just brute-force the plates apart. :-)

Brute-force clutch plate separation: First make sure you have enough oil in the engine (wet clutch), then basically you're looking at either riding it with the clutch lever pulled in until the plates come apart or with the rear wheel in the air CAREFULLY running it in first gear against the rear brake while the clutch is pulled in.

Did you check the main crank drive gear i had a 96 rm 125 with that problem. Its a cheap fix if thats the case but the only problem is that the engine needs to removed and the case needs to be be split. If thats not the problem with the case split it should be ovious.