97 rm 125 clutch adjustment issues

7 replies to this topic
  • ridervt

Posted November 09, 2011 - 04:39 PM


I just put a new clutch kit and cable into the bike and I can not get it adjusted properly. No matter where I adjust it to it lurches when I shift into gear. Why?

  • tmacoo4

Posted November 09, 2011 - 06:32 PM


If it keeps "lurching" then check your clutch basket for grooves and if you have grooves just file them down.

  • Bhavesh

Posted November 12, 2011 - 12:48 AM


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  • jamesrm125

Posted December 23, 2011 - 06:51 PM


mine was doing the same from grooving
i went in today and filed mine down (its cheaper than 200+new one)
now it works like brand new
i also sanded the filed edges down too smooth the filled edges down
look up videos on you tube to pull apart and put back together properly
good luck

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  • clintsmx

Posted December 25, 2011 - 04:49 PM


filing the basket is ok but if you plan on keeping the bike you will need a new basket in time.

  • ridervt

Posted December 27, 2011 - 01:35 PM


I determined that the basket is ok...sounds like it may be a bent shift fork. Saving my pennies to get it done beforespring

  • Tailender

Posted December 27, 2011 - 02:01 PM


A bent shift fork would not make it lurch forward. That only controls the gears position/what gear your in. There is something dragging in your clutch to cause the lurch. Using the correct oil? Soak clutch before install? You could try a lighter oil maybe. My bike does this until it gets warmed up then no lurching.

  • Husa your Daddy?

Posted December 29, 2011 - 04:05 AM


Typical Suzuki issues. Check your basket and hub for notching and burrs. Automotive ATF type F works well in Suzuki's 'less than desirable' clutch components. And as said, soaking your friction plates beforehand is a good idea.

We've still got a 98 125 that sits around if my boys want to go riding with me. It's been a good 10 years now, but I remember reading somewhere that taking the clutches push-rod and filing the squared end (that goes inward) to a more rounded shape will help with your issue... don't know why, but I did it and it helped.

Our 98 has a Hinson basket, a 'like new' OEM hub, good OEM frictions, modified push-rod, ATF, adjusted to a minimal amount of free-play at the lever/perch, and it still drags somewhat, just gotta live with it.


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