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Clutch shaft not engaging after lubing and reinstalling clutch cable
This has happened to me before on my KLR and I managed to pull the shaft a bit up then back into position. With the KLX though I can't for the life of me figure out how to do that. Anyone got any tips?
I need the clutch shaft to go towards the red arrow. But the position it's pictured in is the furthest it would go. And yes, my lever is disconnected and the cable is loose and free on the top end with a lot of free play
The location of the parts in the picture matches my bike setup.
Put a big crescent wrench on that lever and see if you can rotate it towards the front of the bike. If it can be moved, nothing should be jammed inside the clutch. If this is the case, think about how you got it off and redue those steps to put it back on in reverse order.
If that lever is locked, you have something jammed and will probably need to take the cover off to see what happened.
@durielk It was not budging even with a cresent wrench. I drained the oil and took the cover off. The clutch arm mechanism works fine, but the button (called clutch pusher on the service manual) will not move no matter how hard I push it in.
What could it be and what do I do next?
Last edited by cedar-leaf; Aug 7, 2021 at 03:43 PM.
OK, that Clutch Pusher is going to be very hard to move by hand, your pushing against all the clutch springs. If you had it all apart, it maybe something is not right in the clutch basket on reassembly.
Did you put new springs in?
Do you have super high mileage on the clutch basket? After a while those ears where the plates sit get wore and slotted, which would make them hang up.
OK, that Clutch Pusher is going to be very hard to move by hand, your pushing against all the clutch springs. If you had it all apart, it maybe something is not right in the clutch basket on reassembly.
Did you put new springs in?
Do you have super high mileage on the clutch basket? After a while those ears where the plates sit get wore and slotted, which would make them hang up.
I literally did nothing other than disconnect the clutch cable to lube it. And so far I've only taken off the cover to see what's going on behind it.
The bike has 5,000 miles on it and was running perfectly fine
OK, if it rotates, ...make sure you have the flat part looking at the clutch piston.
You did something wrong somewhere, can't believe your clutch basket is locked up when you didn't do anything to it.
Start all over and do it all again. If that don't work take it to a shop.
Clutch shaft not engaging after lubing and reinstalling clutch cable
