Put a new engine in my bike recently, noticed it has a clutch issue. If I put the clutch in with the bike running, and select first, 90% of the time, the bike will die instantly, like the clutch is doing nothing. If I have the bike off, and try roll the bike in 1st with the clutch in, I can feel it resist, like the clutch isn't in. Any idea what to check first? I've been able to get it running a few times and put it in first without it dying, but its rare.
Will it allow you to start in gear, with the clutch in and stand up? Try it - firm grip on the front brake and thumb poised on the kil switch, as it may lurch. If it tries to start, the safety switches are satisfied and it's a mechanical problem. First things first - adjust your clutch! Loosen off the adjuster at the lever Remove the rubber plug on the sprocket cover Loosen the adjuster locknut Back off the adjuster screw, turn it in until it just touches, then back off 1/4 turn Tighten the locknut, making sure the adjuster doesn't move Replace the rubber plug Adjust free play at the lever If that doesn't work, pull the sprocket cover and withdraw the pushrod; a small ball bearing may pop out with it - don't lose it! Is it in one piece, or do you have a snapped-off stub in your hand? Is the ball welded to the tip? Roll it on a flat surface - is the rod bent? Replace any damaged parts; adjust the clutch mechanism. Past this point, you're pulling and inspecting the clutch internals - let us know how you get on, and I'll do some more typing if needs be. Good luck!
