1988 rm80 clutch wont disengage?(or engage..idk much. sorry)

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



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

WITH THE ENGINE TURNED OFF, open the hood and watch the engagement cable. engage mower lever and then disengage the switch sounds happy, possibly the cable is starting to seize up

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

It can't both not engage and not disengage? If you can't put it in gear even with the engine shut off than there is something wrong with the transmission internally. Let me know if you have any questions and I'll do my best to answer them. Thank you for using FixYa.com!

I’m happy to assist further over the phone at https://www.6ya.com/expert/jeremy_d728a59f986299fa

The Clutch on some bikes will disengage the starter motor. Yamaha will not allow you to engage gear when the side stand is down. Hope this gives you some idea

im assuming this is a manual transmission, if so you need to replace the clutch assembly. the clutch disk has worn too thin for the pressure plate to hold at higher rpms and soon wont hold at all.

The clutch assy. is worn out. When a clutch is new the springs on the pressure plate sit flat. When you push on the clutch the springs don't have to move far to disengage, making it easy to press on the clutch pedal. As the clutch wears the fingers of the clutch spring move out, clutch pedal effort and travel increases to the point that the clutch will not disengage anymore. Along the life of the clutch the cable can be adjusted to minimize this. You have reached the end of the adjustment, sorry for the bad news but the clutch needs to be replaced.

possibly the throw out bearing....which is part of the clutch assembly

It's low on freon