Another Clutch Issue...Cannot Disengage!

Littlefreak · March 12th, 2011, 09:15 PM

I've searched and gone through a few threads that have had issues with the bike not being able to engage after a clutch cable replacement. Mine is just the opposite.

My 2003 Ninja 250R clutch cable snapped on me last week. I replaced it following the service manual and the DIY instructions on other sites. Problem is that the clutch will not disengage.
1. With the engine off...I put the bike in FIRST gear and try to roll it forward. It doesn't roll as designed.
2. I pull the clutch lever and it still will not roll forward. ????

I've made several adjustements to the freeplay and have no luck.
I pulled the release lever out and reinstalled it and the cables...no luck.
I pulled the clutch cover off and didn't see anything odd with the release lever or pusher, reinstalled....no luck.
I pulled the spring plate out, checked the bearing/pusher position, and reinstalled everything...no luck.

The old part number for the cable is 54011-1295, and according to ronayers.com I am using the new part# 54011-1261
Before the original cable snapped, everything was shifting smooth. I just bought the bike a month ago.

Please help!! What am I missing? Did I somehow screw something up upon removing the old cable for the clutch side adjuster/release lever?

scotty · March 12th, 2011, 09:45 PM

Is there any play in the cable at all? The cable should be tight though out the whole system and the lever should only have about a nickel worth of play.

Littlefreak · March 12th, 2011, 09:50 PM

Quote:

Originally Posted by scotty

Is there any play in the cable at all? The cable should be tight though out the whole system and the lever should only have about a nickel worth of play.

The only play in the cable is the slight freeplay in the cable at the lever's (clip-on) end...per manual.

kkim · March 12th, 2011, 10:23 PM

when you work the clutch lever in and out, is the release lever on the engine end of the clutch cable turning as it should?

Littlefreak · March 12th, 2011, 11:37 PM

Well it doesn't seem an issue anymore, and I'm wondering if this is normal 250R behavior when the bike is cold. I warmed it up and it seemed to loosen up a bit. Took it for a short test ride and there were no issues. I'll re-adjust the cable in the morning, but the bike is shifting great. Sorry for the false alarm, but thanks for your concern and respones guys.

CZroe · March 12th, 2011, 11:45 PM

Having the clutch lever pulled with the bike in 1st gear is definitely not the same as neutral (the tire will spin if the bike is lifted), but it still should not have felt like you couldn't move it. Was the tire possibly wedged in a pavement hole or something?

Littlefreak · March 13th, 2011, 07:13 PM

Took it for a 200 mile ride today after the final cable adjustments. Everything seems in order. I'm a happy dude.

mrlmd · March 13th, 2011, 07:40 PM

Sometimes these bikes get "sticky" clutch plates from the cohesive effects of the oil between the plates if the bike hasn't been used for a while. Pull in the clutch, rock it back and forth for a few seconds and it should loosen up and release. Occasionally you'll see it lurch forward as if in gear even with the clutch pulled in when you try and start it. Just ride it, it'll loosen up and go away, it's almost normal behavior and nothing to worry about.

Littlefreak · March 13th, 2011, 09:15 PM

Quote:

Originally Posted by mrlmd

Sometimes these bikes get "sticky" clutch plates from the cohesive effects of the oil between the plates if the bike hasn't been used for a while. Pull in the clutch, rock it back and forth for a few seconds and it should loosen up and release. Occasionally you'll see it lurch forward as if in gear even with the clutch pulled in when you try and start it. Just ride it, it'll loosen up and go away, it's almost normal behavior and nothing to worry about.

Sounds right to me. While this issue was a pain in the butt, it allowed me to get more familar with the bike.

March 12th, 2011, 09:15 PM	#1
Littlefreak ninjette.org newbie Name: David Location: San Diego Join Date: Mar 2011 Motorcycle(s): 250R & ZX-10R Posts: 6	Another Clutch Issue...Cannot Disengage! I've searched and gone through a few threads that have had issues with the bike not being able to engage after a clutch cable replacement. Mine is just the opposite. My 2003 Ninja 250R clutch cable snapped on me last week. I replaced it following the service manual and the DIY instructions on other sites. Problem is that the clutch will not disengage. 1. With the engine off...I put the bike in FIRST gear and try to roll it forward. It doesn't roll as designed. 2. I pull the clutch lever and it still will not roll forward. ???? I've made several adjustements to the freeplay and have no luck. I pulled the release lever out and reinstalled it and the cables...no luck. I pulled the clutch cover off and didn't see anything odd with the release lever or pusher, reinstalled....no luck. I pulled the spring plate out, checked the bearing/pusher position, and reinstalled everything...no luck. The old part number for the cable is 54011-1295, and according to ronayers.com I am using the new part# 54011-1261 Before the original cable snapped, everything was shifting smooth. I just bought the bike a month ago. Please help!! What am I missing? Did I somehow screw something up upon removing the old cable for the clutch side adjuster/release lever?

March 12th, 2011, 09:45 PM	#2
scotty ninjette.org certified postwhore Name: Scott Location: Carlise Ohio Join Date: Apr 2010 Motorcycle(s): Yahama v star 650 classic Posts: A lot.	Is there any play in the cable at all? The cable should be tight though out the whole system and the lever should only have about a nickel worth of play. __________________________________________________

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March 12th, 2011, 10:23 PM	#4
kkim Join Date: Nov 2008 Posts: Too much.	when you work the clutch lever in and out, is the release lever on the engine end of the clutch cable turning as it should?

March 12th, 2011, 11:37 PM	#5
Littlefreak ninjette.org newbie Name: David Location: San Diego Join Date: Mar 2011 Motorcycle(s): 250R & ZX-10R Posts: 6	Well it doesn't seem an issue anymore, and I'm wondering if this is normal 250R behavior when the bike is cold. I warmed it up and it seemed to loosen up a bit. Took it for a short test ride and there were no issues. I'll re-adjust the cable in the morning, but the bike is shifting great. Sorry for the false alarm, but thanks for your concern and respones guys.

March 12th, 2011, 11:45 PM	#6
CZroe CPT Falcon Name: J.Emmett Turner Location: Newnan, GA Join Date: Apr 2009 Motorcycle(s): '08 CP Blue EX250J, '97 unpainted EX250F, 2nd '97 unpainted EX250F (no engine), '07 black EX250F Posts: A lot.	Having the clutch lever pulled with the bike in 1st gear is definitely not the same as neutral (the tire will spin if the bike is lifted), but it still should not have felt like you couldn't move it. Was the tire possibly wedged in a pavement hole or something?

March 13th, 2011, 07:40 PM	#8
mrlmd ninjette.org sage Name: Marc Location: Crawfordville, Florida Join Date: Jan 2010 Motorcycle(s): 2005 Suzuki S50, 2006 Kawasaki Ninja EX250F, 1990 Honda PC800, 2000 Yamaha TW200 Posts: 848	Sometimes these bikes get "sticky" clutch plates from the cohesive effects of the oil between the plates if the bike hasn't been used for a while. Pull in the clutch, rock it back and forth for a few seconds and it should loosen up and release. Occasionally you'll see it lurch forward as if in gear even with the clutch pulled in when you try and start it. Just ride it, it'll loosen up and go away, it's almost normal behavior and nothing to worry about.