REPLACED CLUTCH ON ZR 550 CLUTCH ENGAGES , BUT WHEN FULLY RELEASED BIKE JUDDERS THEN STALLS OUT . TRY TO ADJUST & GEARS WONT ENGAGE .

check the clutch adjustment as the installed cable is too loose to fully disengage the clutch
talk with a bike shop if it is difficult tot adjust correctly

Did you adjust tension on the cable correctly? If all is installed correctly, then you have to check the gears - they may be worn.

ok, adjust your clutch cable, did your clutch basket look notched, that happens with old cr 500's a lot

In which case the clutch is not properly dis-engaging. Adjust the clutch cable properly, if this still doesn't fix it you will need to replace the clutch friction plates at the very least.

In the past when I adjusted the clutch on my Virago, I would have the bike in gear...with engine off, make sure pulling in the clutch allows the bike to roll..... Then with the engine running I would adjust for the point at which the clutch would begin to engage upon release. Make sure when released, the clutch is fully engaged and isn't slipping.

Hey Dennis, sounds like it might be time to adjust the clutch...( at the engine).. get a service manual for your bike,,it will be a wealth of info for you..

Motorcycle Service and Repair Manuals

A high clutch pedal is good.
There should only be about a half inch of pedal freeplay, before you start to feel resistance.
So the clutch should not engage until it is almost fully released, near the top.
The makes shifting the easiest.

If the shifting is difficult when cold, then put the transmission in neutral and let the clutch out when you warm up the engine.
That will warm up the transmission oil.

Of course you could also check the transmission oil level and change it.
But your question makes me believe you may need more experience on a stick shift. Make sure you do the H pattern carefully, and do not get lazy and turn it into an X pattern.

Check your cluth adjustment , adjust if possible .

This is a problem that is very hard to solve on line... It could be human error.. But it could be because of power or carburation issues as well. Best thing I can tell you is to remove the spark plugs and tell me what color they are. Spark plugs are an excelent indicator of the true performance of the engine. Attach pictures of the porcilan and electrode area. This will help me determine if it is error or not.

sounds to me like your friction plates in your clutch assy. are worn down to much.