Clutch doesn't release properly.

G19RKE · Borekit Bruiser Joined: 29 Jan 2013 Karma :

Picking your brains again.

It's an Aprilia rs 125 2000 reg.

The bike starts fine and ticks over nicely and actually rides fie once its moving. I fitted a new clutch cable and removed the clutch basket and everything looked fine and had plenty of life left in it. I have adjusted the clutch basket inside the casing too But it still won't release fully. When i fitted the new clutch cable i had to wind out the adjuster on the clutch lever just to take up the slack. Even with the clutch pulled all the way in the bike is still trying to roll forwards so I end up pulling the brake to stop it and then it cuts out if I don't keep the revs up.

This is making this otherwise enjoyable bike of mine quite annoying to ride when I come to junctions as I'm stalling it 8/10 times. Lol

andy_uk · World Chat Champion Joined: 13 Aug 2011 Karma :

The do drag a bit when cold...
Are you using the right grade gearbox oil? (75w90)
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Aprilia Classic 125, GS500E, ER5-A1, ER5-C4, ER6 & an XJ6 project frame...

P. · Red Rocket Joined: 14 Feb 2008 Karma :

10w40 works fine in them.

They shouldn't drag when cold.

Did you adjust the actual adjuster on the clutch side first. Set the lever so it has no adjustment at all, so all the way in.

Adjust the engine end so you feel some resistance, then back off 1/4 turn. Lock it and then adjust the free play at the lever end.

G19RKE · Borekit Bruiser Joined: 29 Jan 2013 Karma :

Surely it shouldn't drag at all when the clutch Is pulled in. An yes I fitted new cable with adjuster all the way In on the lever and adjusted the clutch at engine end and locked off but engine end is almost at max adjustment now and so is adjuster on lever. Is it time for a new clutch?

G19RKE · Borekit Bruiser Joined: 29 Jan 2013 Karma :

Can't remember what oil it was exactly but it was putoline gearbox oil which was purchased based on the Haynes manual I have for the bike so that cannot be the issue.

R1stu · Shrek! Joined: 12 Mar 2003 Karma :

Ive got the exact same problem with the ninja. fitted a brand new cable and the adjuster is on last thread both clutch and lever end.

but it still clunks into gear and lever is almost on bar before disengaged enough.

Is that worn plates? the push rod bit is was past center.
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Current bike 1991 Honda ST1100 Pan European, 1986 Honda cb350sg (Finished)

G19RKE · Borekit Bruiser Joined: 29 Jan 2013 Karma :

I thought it could be the plates worn also but it was fine when I removed them to check. It may b the issue with yours if you have put a groove in them but mine were fine so i refitted them back to the bike. I'm thinking of changing the whole lot now though in hind sight.