Yz 125 2001 stays in gear when clutch pulled in

Clutch problem - please help - Dirt Rider Magazine

forum.dirtrider.com/discussion/6668452/clutch-problem-please.../p1

May 11, 2012 - 18 posts - ‎9 authors
If I put it in 1st with the clutch pulled in, it will not roll freely, either the tire will slide ... The cluch is not dis engaging in my opinion. ... it (even with the clutch lever pulled in) the clutch won't disengage, and it will drag the tire or turn the motor over. ... can get notched, however - if your bike shifts into gear (with the clutch pulled in) ... bike not able to roll when in gear even while holding ...
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Clutch Problems (Lever Won't Engage Clutch after cable change ...

www.xr1200ownersgroup.com/site/showthread.php?t=12314

Mechanical issue: clutch not disengaging completely...
engine off - put in gear and roll back and forth with clutch released does engine stop the bike from rolling? Now pull clutch lever in and try rolling again is clutch cable adjusted properly?
Electrical issue: bike thinks clutch is still engaged and kills motor when not in neutral
Is the clutch switch properly connected and working? Is it adjusted properly? Use a multimeter to read resistance across switch contacts does it change state when clutch is pulled in?

Good news, you just need adjust the clutch cable..

Always order the part for your model and year when getting parts and make sure it matches in length with the old one. Note how much cable is sticking out of the housing.
Is it 3 1/2 inches or 4 inches or 2 inches. make sure the new one matches.

Put the new cable on with lots of slack.Slack at the adjuster, and slack at the handlebar adjuster
Now pull the lever in, it will be easy because of the slack.let it stay there.
It will stay against the grip.
As you tighten the cable adjustment down by the cover, you'll notice the clutch lever move out.
Once it reaches the top, stop adjusting and pull it in again.
Continue adjusting and pulling the lever until the lever springs back to the top.
You can feel resistence which is the clutches disengaging.
Make sure there is 1/8" free play when the lever springs back.
Now turn the clutch cable adjust on the handlebar outward, which will remove the rest of the slack.
Only leave 2mm slack on the lever.

Now start your bike up and it should work like new.
You want your clutch to disengage within the first 1/2" of pulling the lever in.
This ensures the clutches are definately disengaged by the time you get the lever pulled back to the grip when shifting.

If your clutches are slipping or dragging no matter how you adjust the cable then your clutches may need replaced.
But sounds to me like its just an adjustment.
Hope to be helpful
Big Al

Your clutch is grabbing, adjust the cable so that it pulls harder on the clutch. If this does not help you may need to take the cluth out and inspect it for bad springs or damage

First thing is to make sure you don't have motor oil in the engine. Wet clutches and motor oil are not compatible. Use only the oil sold at motor cycle shops. Do that before tearing into the engine or making any radical adjustments. Good Luck -Ned-

hi m8,,this might sound stupid,, but in winter dayz and salty conditions ,cables corrode in side,,so i can start some where to help,, 1st take the cable off the handle bar,, and the clutch casin,,get a little bit of oil in a jam jar or any thing like that,,dip one end of the cable in the oil ,and keep pullin and pushing the inner cable as if u were trying to draw oil up threw the inside of the cable ,, turn cable the other end and repeat,, try that 1st m8,, still have probs come bk, and il go threw the next step,,

You are saying that with the clutch lever pulled in the bike still wants to go forward. Generally that is caused by dirty, gritty oil in the gearbox. Go ahead and change the oil. 10w40 motor oil is what you want. I think that will fix the problem assuming the clutch plates were installed properly. The first plate installed and the last plate installed should be a fiber friction plate, 8 plates total. A metal pressure plate goes between each fiber plate, 7 plates total.

Be sure the lever assembly arm is installed so that it gets full movement of the clutch cable. If the full range of movement is not present then full disengagement of the clutch is not going to happen.

cape cod bob did you a good service in the manual referral. Be sure to say thanks.

the plates will stick to each other because of oil
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

Your clutch is not fully disengaging.Adjust the cable at the lever until you have plenty of free play.Then adjust the cable at the motor until you have full engagement then readjust lever to 3/8 in play.Fine tune at the motor.It may take a few trys but you can get it.

hey dude,, just thought id come in and give u some tips or 3,, i take it when u pull clutch lever in, and try and change gear it feels like your foot will snap b4 it goes in gear,, if that makes sense,, firstly mate,is to make sure the clutch cable slides freely ,easest way is to take cable off and just grab 1 end and make sure it isnt sticky,, if so dip one end of the cable in a bit of old oil ,,whilst holdin the other end ,pull and push the cable inner, this will **** up a bit of lubricant inside the cable ,, keep doin this each end till free to move, ,,next step if the cables ok,,, and may need help if u dont no,drain the oil out,,and as u r sat on the bike is to remove the clutch casing on the right hand side of the moter,where the bottom end of the cable goes,remove the casing being carefull not damage the gasket,,then u will see clutch plates and friction plates housed,, undo the 7 or 8 spring loaded bolts carefully take the first fibre plate out then metal friction plate then another fibre plate and so on,, wen u take the 1st plate out place that on the bench ,stacking each plate on top of one another, cause they have to go back in as they came out,,wen out,,u need a piece of wet n dry paper ,or fine emery,,and just wipe round both sides of the fibre plates taking the shine off them,as u put them back in,, put casing back on with a decent gasket,, oil back in cable on, make sure cable has no free play on the lever so wen u r about to pull lever in it bite straight away,, start her up, warm it up and try it,,any probs still il eat my shoe,, take care m8