I'm not going to mentionthe fact that this is happening on a 1978 suzuki rm400, but here it goes. My cousin just gave me a 1978 rm400 for free. all it needs is a throttle cable. anyways, when I put the bike in gear and pull in the clutch, it is like the clutch isn't even there. The rear tire locks up and i can hear the piston slowly turning over.
At first I figured the cable was out of adjustment, so i adjusted it....and adjusted it...and adjusted it. Nothing. So i now figure that the cable is strectched far beyond the adjustment will allow for. Just to make sure, I attached a vice grip pliar to the clutch shaft coming out of the engine and turn the shaft until it will turn no further.

While my neihbor proceeded to push the bike in gear while i held the clutch lever as far up as it travels. Nothing changed. tire dragged, piston turned over.
Next we take the clutch cover off and proceed to take each clutch plate off and inspect it. Everything was in great shape. we put the thing back together and the situation didn't change. What gives? does anyone have any suggestions as to what the problem is? Thanks for taking the time to read the long post.

JaMes

 

You need to take the outer clutch basket off the inner bushing is probably frozen to the main shaft and wont freewheel like it should. The bike has been sitting around for a long time and the bushing has probably dried out.

 

thanks for replying. Do you think the bushing is ruined or just needs to be broken loose?
Thanks again for replying.

JaMeS

 

yamahagye, We don't even know if this is the problem yet. I guess you will find that out when you pull it apart!!!!!!!!

 

iI had a banshee do that I pull started it then drove it with the clutch pulled in and it free'd up,a mechanic told me to do this ,it toke about 5 mins. but the clutch was always sticky after that

 

Thanks guys for posting. I ordered my new throttle cable last sunday with 2 day shipping and I just got an email today saying that it will be here april 3rd. i'm going to my friends house today and am gonna borrow a mo-ped throttle cable to rig up to see if it works. I'll try holding the clutch in and riding around.

JaMeS

 

The clutch disenages fine once the engine is started. It still doesn't disengage when the motor is off, but oh well. My friends moped cable didn't work so i had to modify a brake cable off of a bike. It works great. Thanks for the help guys,
Laterz