Rmz 250 09 model with new clutch cable fitted must be adjusted fully out to get clutch to operate

The clutch is not releasing , several things can be the cause, check the following , Throw out bearing same size,clutch driven plate not fitted back to front, clutch fork is fitted to throw out bearing housing and pivot mounting, is the slave cylinder rod the same length, has the clutch free play been adjusted, has all air been bled from the master cylinder, If cable operated has free play been adjusted. Has the new pressure plate the same throw as the old one.

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.

I am not familiar with your model. However what I can think of that would cause the symptom you have with a basket case assembly: Improper clutch assembly( pressure plate not engaged properly with inner clutch hub; needs to be rotated 1 or more teeth so as to seat fully on plates), improper plate stacking or # of plates. Incorrect location of clutch cable mounting bracket. If clutch arm is of the splined type, incorrect placement on the splined release shaft. hope something helps

The clutch cable is fitted to the lever and the clutch arm on the top of the crank case beside the oil cap. Remove old cable (remove side fairing if you need to for access to cable end) slacken the new cable adjusters as much as possible fit to the clucth arm on the engine and fit to its seat route the cable the same as the old one up to the clutch lever, fit the cable end to the lever, hold the cable sleve tight pull the lever to strech the cable and drop into the lever seat, adjust the cable for 2mm of free play at the lever before the cable is pulled

sounds like the clutch needs to be adjusted

There are 2 types of cable used. Auto Adjust...and Manual Adjust. Either are easy to fit. Remove tray over foot=pedals will allow you to access one end of the cable. Here the cable simply hooks over the pedal linkage. Remove the outside plastic panel in front of windscreen to allow the cable to be installed. If the cable is the Manual Adjust type, loosen off the adjuster nuts at the clutch lever on the front / side of the gearbox and pull out cable.
If car is fitted with Auto Adjust cable...A Plastic Retainer Strap will be installed on the cable at the gearbox end. This retainer should be latched into place before removal. If the cable is broken at present you need not bother with this retainer. A new cable comes with this retainer already fitted. Its simply a matter of fitting the cable in place at both ends and then releasing this retainer. Do NOT release this until the cable is fully installed at BOTH ends
John

To remove the old cable first shorten the mid-cable adjuster to give as much free play as possible. If you need more free play screw in the adjuster at the clutch lever as much as possible and line up the slots so you can disconnect the cable from the clutch lever. Then remove the shift lever, and possibly the left footrest if needed to remove the front sprocket cover. Remove the cotter pin and disconnect the cable from the clutch release lever. Make a note of the routing of the old cable so you can replace it. Install the new cable with a new cotter pin at the lower end first, and route it the same as the old cable. To adjust the new cable, shorten the mid-cable adjuster as much as possible. At the clutch lever, turn the adjuster in and leave about 1/4" of threads showing between the locknut and the lever body. With the front sprocket cover still off, loosen the locknut on the clutch release lever and back the screw 3 or 4 turns. Turn the clutch adjusting screw in until it becomes hard to turn and then back it off 1/2 of a turn and tighten the locknut. Now lenghten the mid-cable adjuster until there is no free play and tighten the locknuts. Check that the lower end of the cable is fully seated in it's socket. At the clutch lever, turn the adjuster in so you have 1/16" free play, and tighten the locknut. Replace the front sproket cover and the shift lever and footrest.

the clutch cables dont really adjust if its still to long after fitting a new clutch then i suggest that a new cable fitt4ed aswel as it seems to have stretched

first i would try adjusting the clutch cable because commonly people with think that they're clutch is going out when really just the cable has gotten stretched....try adjusting that first and if that works then you should be fine for another couple thousand miles but if you want to not have to worry bout it for awhile i would just replace teh clutch assembly....usually ranges from $200 to $450 depending on the clutch set and the mechanic that does the work for you. Let me know what happens. :)

DEar Customer,

your from is that your car is front wheel drive & you have to reset your car clutch point that loose its sensitivity as they had before,

its not a big prib you have to open bonet than make more active clutch wire with streching clutch joints.

THNX