Motorcycle Repair: clutch problem, clutch lever, clutch basket


Question
Hi, i recently purchased a 1995 suzuki RM125. I tried to take it for a ride today but its doing something odd, i it starts fine and doesnt die out but when i have the clutch pulled all the way and i put it into 1st the instant i do the bike pulls and dies instantly even though i didnt let go of the clutch, now when i have it in neutral i am able to move the wheels no problem. im not sure what it could be. thank you

Answer
Dan,It may have two problems. Lets go for the cheap one first.Locate the cable on the engine and loosen the locking nuts and pull the slack out of the cable. Make sure the clutch lever adjustment is all the way in. Pull the cable on the engine case untill you feel the clutch resistance and back off a little and lock the nuts.Now make the fine adjustment on the lever and leave about 2mm slack between the lever tip and the perch before pulling the cable. This should release the clutch so it will release when you put it in gear. If it wont release the we go for the expensive fix. The clutch basket is worn with notches from the drive discs and not floating gree when the clutch lever is pulled.The basket part# 21200-43D04 $180.00 The discs (8) 21441-43D00 are about $13.50 and (7) 21451-43D00 $6.30 each. Also inspect the release bearing and you will need new side cover gaskets and fresh oil and coolant. This might cost you about $400.00 if you do it yourself.