The bike would die when put in gear, so after lots of searches we decided it was the clutch. After taking it apart and looking at the components everything looked fine. We then changed cdi's, put it back together, and now it stays running when put in gear but it doesn't actually engage. Not sure what we did wrong, we followed the directions in the repair manual. What else can we check???? Does it need to be "in" gear when we put it back together or some other "trick"? Any suggestions??? This is a 1998 without es.
Thanks

 

It sounds like you had 2 seperate problems. I had a CDI that went bad with the same symptom. The engine would quit when put in gear. So, anyway, you have that fixed. My guess on the other problem of not engaging is that you didn't get something back together correctly or that the clutch needs to be adjusted.