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The clutch will not disengage 1980 Suzuki GN400

I have taken apart my clutch & inspected it. everything appears to be ok, however, my clutch won't disengage & when I loosen the bolts to loosen the springs even a slight bit it won't engage? I have worked on many clutches before but none quite like this... @

Posted by Anonymous on

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  • Suzuki Master
  • 59,789 Answers

Hi, Anonymous and the usual suspects are:
1. Clutch not properly adjusted.
2. Clutch plates rusted together.
3. The hydraulic clutch needs bleeding.
4. Faulty clutch slave cylinder.
5. Faulty clutch ramp mechanism.
6. Broken clutch rod
7. Clutch pack loose on the main shaft.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://www.suzuki-forums.net/index.php?/topic/3942-clutch-not-disengaging
https://www.youtube.com/watch?v=zM_oYxlTRHk
https://www.tradebit.com/filedetail.php/97159274-suzuki-gn400-motorcycle-factory-service-repair $15
https://www.partsfish.com/oem-parts-for-suzuki
http://mybikemanuals.com/suzuki

Posted on Apr 22, 2019

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6 Suggested Answers

6ya6ya

6ya staff

  • 2 Answers

SOURCE:

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Posted on Jan 02, 2017

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Anonymous

  • 2336 Answers

SOURCE: 1100 wierd clutch disengage problem

Bleed your slave cylinder on the sprocket cover and refill the hydraulic fluid. If you have any leaks you will get air in the system and it will not fully disengage the clutch. As for the 750, they have cable clutches and you just need to adjust the slack of the cable.

Posted on Nov 20, 2008

Savu Mihai

  • 211 Answers

SOURCE: Clutch spring keeps coming undone, starter won't engage

Hi

The clutch is a centrifugal mecanism.When you pull the starter cord the chain gear is engajed by the clutch.The clutch has to work properly.Change the 3 clutch with new ones(the old ones are tighten)
Hope this helps.

best regards savumihai71

Posted on Dec 07, 2008

tellme2

terry weightman

  • 137 Answers

SOURCE: 91 kx 250 clutch too tight

hi m8,, wen u put spring bolts and springs on,, u must do them right up ,, untill the spring is completly comprest,, ,untill the spring bolt wont do up any more,,cheers

Posted on Jan 23, 2009

kmrmike

  • 3 Answers

SOURCE: just replaced clutch spring on '01 vulcan 1500

assuming it was reinstalled properly....try the following. while bleeding the system, squeeze the clutch lever several times to pump up the system as normal; open the bleed screw while holding the clutch lever in and air or fluid comes out. instead of closing the bleed screw hold your finger over the bleed screw and pump up the clutch lever in the normal fashon and bleed by releasing your finger to let the air escape try this several times to see if your clutch comes back. I don't know why but this technique works sometimes...Mike...Make sure you always have plenty of fluid in the resivoir at all times

Posted on Mar 31, 2009

tombones

  • 3567 Answers

SOURCE: Clutch will not disengage

Chances are the clutch lever assembly (where the cable attaches to the gearbox) has gotten out of position on the Axle push lever (the shaft that goes into the side cover and the lever is attached to). The shaft is splined for the lever to attach. Re-fit the lever on the shaft and try it now. If the splines are stripped then you may need to drill a 1/8" hole through the lever and shaft then insert a 1/8" cold roll split pin to anchor the two together.

The bottom of the axle shaft fits in the side cover and actuates a lever to separate the clutch plates. This mechanism could be bad.
If that is the case then get the entire COVER ASSEMBLY part number 5NY-15490-00. The assembly comes with a new shaft.

The clutch cover mount bolts should be 8 to 10 ft. lbs. This is not a factor in your problem.

Please rate this answer. Thanks Geoffgiggy!

Posted on Apr 11, 2009

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2 Answers

Suzuki RM80 clutch will not disengage.


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
clutch adj-1yabyasfolpfscp5rjzzy1he-2-0.jpg

clutchbasket1-1yabyasfolpfscp5rjzzy1he-2-2.jpg clutchparts-1yabyasfolpfscp5rjzzy1he-2-5.jpg
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.
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I have a suzuki rf900 with a clutch that won't disengage I have taken clutch apart and separated plates and rebuilt but didn't solve problem any more suggestions please ?


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HTH

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Hi, Anonymous and the usual suspects are:
1. Clutch not properly adjusted.
2. Clutch plates rusted together.
3. Hydraulic clutch needs bleeding.
4. Faulty clutch slave cylinder.
5. Faulty clutch ramp mechanism.
6. Broken clutch rod
7. Clutch pack loose on the main shaft.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Tricks on how to free motorcycle clutch that won disengage Live demo on...
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Kawasaki 1982 KE175 Service Repair Manual
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http://mybikemanuals.com/kawasaki

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1 Answer

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I know it sounds silly, but have you checked your earth or ground wiring. If not earthed this type of problem can occur. Did the bike run before you replaced your coil etc? You could have a crook CDI
are you using multi meter mate for correct voltage readings?

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Hi, Scott it's possible otherwise the usual suspects are:
1. Clutch not properly adjusted.
2. Clutch plates rusted together.
3. Hydraulic clutch needs bleeding.
4. Faulty clutch slave cylinder.
5. Faulty clutch ramp mechanism.
6. Broken clutch rod
7. Clutch pack loose on the main shaft.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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Hi, Phxsmith6880 and the usual suspects are:
1. Clutch not properly adjusted.
2. Clutch plates rusted together.
3. Hydraulic clutch needs bleeding.
4. Faulty clutch slave cylinder.
5. Faulty clutch ramp mechanism.
6. Broken clutch rod
7. Clutch pack loose on the main shaft.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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https://www.partsfish.com/oem-parts-for-suzuki
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