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Kawasaki KX80 the clutch will not engage

Cant put my kx80 into gear, clutch won't engage clutch cable and lever are working fine, it's like the clutch is hanging up. the oil appears to be dirty in the case eyelet, do I replace the oil? engaging the lever the bike won't roll freely. @

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  • mike Dec 21, 2011

    the gear shifter wont let me shift with the lever pulled .I can push start it then the gears do shift while riding



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  • kawasaki Master
  • 58,590 Answers

Hi, Mike and the usual suspects are:
1. Clutch cable adjusted too tight.
2. Pressure plate center screw adjusted too tight
3. A broken clutch rod.
4. Slave cylinder piston stuck.
5. Clutch plate missing from the clutch pack.
6. Clutch plates have worn past minimum specifications.
7. Clutch plates crystallized due to incompatible oil.
8. Broken transmission shafts or gears.
9. Rear drive belt or chain broke.
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.
Clutch does not engage
kx80 clutch won engage Kawasaki Motorcycle Forums
Kawasaki KX60 Service Manual
OEM Parts for Kawasaki
1990 Kawasaki KX80 Owner Manual

Posted on Jul 25, 2018


6 Suggested Answers

  • 2 Answers


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Posted on Jan 02, 2017

  • 12 Answers

SOURCE: bonneville stalls when i engage first gear

there is a plunger type side stand switch located where side stand is bolted to the frame. road **** builds up on it and it gets stuck in.. pull out with pliers and grease it.. regards jeff

Posted on Mar 25, 2009

  • 2712 Answers

SOURCE: Long clutch pull/engagment on 696?

I recently installed CRG levers on our 696. No boot to fiddle with on this model. You can see the Allen key on the back of the lever perch from the outside or bar end. Simply adjust the Allen screw in/out with an Allen socket and ratchet to a range of positions then check clutch engagement and drag via a few test starts. Too far one direction and the clutch hangs up while too far the other way can give you an off/off switch lacking in full engagement that is hard on the gearbox. Conservatively set after 15 minutes of adjusting and testing resulted in an incredible reduction in the distance that my wife had to reach her tiny hands. She was extremely pleased as this completely addressed her only real complaint and made it much easier to ride. I did take the more expensive route with the Termi cans, getting a bit of a break from my local dealer at about $1250. The upside I found was that there really is no need for the dealer to install the cans because re-mapping wasn't necessary as it was with my 1098. If you are capable of unbolting your gas tank (a gazillion Allen screws on the tank covers and three bolts on the tank) and have a spare set of hands available to hold it so you don't have to undo fuel lines it is fairly simple. It's a good idea to take the tank covers off so you can see where everything is hiding. While you are under there with the battery disconnected I recommend installing a battery charger pigtail so you can easily plug in a trickle charger for the off-season. I spent maybe two hours - less time than on the fender eliminator. Again as I found putting Termi cans on my1098 the 696 loses the irritating leanness, starts much easier (fast idle no longer necessary) and runs much cooler. Plus it's all covered under warranty. With the removable sound deadener inserts you have a much nicer sound in your choice of "mellow" and "heavy metal". In my mind it now sounds like a Duc is supposed to sound. One trick on the install: the new CPU caused my dash to switch to EU (km instead of miles). There is an excellent detailed thread on this site that shows how to change back to US settings. Takes about two minutes.

Posted on Nov 20, 2008

  • 476 Answers

SOURCE: 1999 1400 intruder does'nt have any pressure when engaged.

Maybe, and maybe not. If it is a problem with the master cylinder, then it could be bleeding back into the reservoir.

If it will not pump up and pressurize, and there are no signs of a leak, then you need to look at the master cylinder.

Posted on May 11, 2009

  • 408 Answers

SOURCE: 1998 kdx 200 clutch will not dis-engage

The clutch's plates must be stuck.Disassemble them and renew if necessary.The clutch lever should have 3mm freeplay and the spring's bolts should be tighten at 14Nm.

Posted on Jun 09, 2009

  • 125 Answers

SOURCE: Backing up with reverse gear bike just stopped. It

Pull out on the lever and push it toward the front of the bike, hard if necessary. Rock the bike while pushing. If the bike comes out of gear it should start. The bike will not start while the lever is up.
Probably need to replace the switch behind the lever. Don't test it, just replace it.

Posted on Jun 15, 2009

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1984 KX80 I pull the clutch in and it won't engage into gear it just revs as though it is still in neutral

Hi, Brad and the usual suspects are:
1. Clutch not disengaging.
2. Bent shift shaft.
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4. Gear seized on the shaft.
5. Gear positioning lever binding.
6. Shift return springs weak or broken.
7. Shift return spring pin loose
8. Shift mechanism arm spring is broken.
9. Shift mechanism arm is broken.
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Clutch problem??

Sounds like the clutch release is not seating smoothly and fully. Operate the release very slowly (preferably out of gear while static or can you put it in 6th while its off? and see if there's any stiction in the clutch release mechanism.Maybe the clearance changes in 6th gear but i cant see why it should.

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Clutch lever won't engage on 2005 honda rebel

Hi, Anonymous and the usual suspects are:
1. Clutch cable adjusted too tight.
2. Pressure plate center screw adjusted too tight
3. A broken clutch rod.
4. Slave cylinder piston stuck.
5. Clutch plate missing from the clutch pack.
6. Clutch plates have worn past minimum specifications.
7. Clutch plates crystallized due to incompatible oil.
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 assuming you put the clutch back togethere in correct order you remove it does the clutch lever have end play in it when you releace it there should be some play in it if there is not you need to loosen it ether at the lever holder or at the set screw where the cable on the engine case lossen it then turn it until it lighly stops then back it off quarter of a turn.

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Cant get clutch to engage after fiting new cable help please

the clutch may be stuck on. Put the bike in neutral, start the bike, run down the road looking like a fool jumping on and off the bike to kick it into 2nd gear and pumping clutch lever. Clutch should be free.

It might also be worth checking if your pushrod has a ball bearing in the end, I had one on mine, replace the clutch plates and it wouldn't work with the ball bearing in :)

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I have a 1983 honda magna v45. I got the bike from someone that hasn't messed with it in about 6 years. After about the last 2 months of cleaning the carbs i got it running. Now when i put it in gear its...


Have you checked to see if the clutch lever is working properly? If the clutch stays engaged, the bike won't move. You can lubricate the clutch cable by removing it and taping a cardboard cone to the housing and pour a lightweight (30w) motor oil into the cone. Next, move the cable back and forth for a minute or so so that the oil will flow down inside the cable.

If the clutch cable is working correctly then then clutch plates are not disengaging when put into gear. Try different gears to see if it does the same thing. Also, have you changed the oil in the bike? Your bike uses a wet clutch system which means that the oil you put in the crankcase is also used for your clutch plates. Using a synthetic oil will cause problems with your bike (according to Honda).

Hopefully this will give you a few more ideas to try. If you need more information, please post a reply/comment and I will get back with you.

If you find this information helpful, please vote on this post. Thank you.



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1 Answer

I have a suzuki rm 125 1994 model when i pull the clutch lever in to put it in gear the clutch doesnt work t jst crunches into gear

Adjust the clutch cable to allow about 1/4" free play at the end of the clutch handle. Don't put the bike in gear until the rpms are near idle speed. The clutch is working fine if the bike does not lurch forward when going into gear at idle speed. Dirty, gritty oil in the gearbox can make the clutch grab. Consider changing oil if grabbing is the problem. The "crunch" you hear is the slider gear engaging into the driven gear. The higher the engine speed when being put into gear the louder the crunch. The slider gear engaging "dogs" can break. Crunching into gear is hard on the gears.

Post a comment to let me know how you come out on this.

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2 Answers

New clutch cable made gear change much worse.


Had a recent similar problem. Fortunately, my replacement cable is adjustable. As the new cable stretched, I had to take a crowbar to the the throwout lever next to the battery and lever it back while pulling off the cable (towards the battery). I then lifted the fuse box (look out for the 10mm plastic nut that holds it in on the side by the driver's side fender) on the drivers side right in front of the windshield to reach down and pull the cable up enough to reach the adjustor. When it is high enough, release the locknut and turn the adjusting nut upwards about 4 turns (both nuts on my cable were 17mm and a "stubby" is handy but not necessary. Grab the end by the battery and, making sure it is seated on the groove on the transmission, pry the lever again with the crowbar and reseat tg
he cable end in the lever. I have had to readjust the cable twice more before it settled in a comfortableplace, but once you get the hang of it, it only takes about 10 minutes.

Hope this is helpful.

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1 Answer

Clutch wont disengage properly

What kind of oil is in the crankcase? Wet clutches take a sprcial oil, noy motor oil. If oil is correct, Is the cable and release levers fully disengaging the clutch? There is an adjustment for the rod inside the clutcjh hub . That could be short stroking.

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check the clutch lever at the motor and make sure it is moving the arm that pushes the pressure plate and make sure it is moving

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