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Author Topic: 87 Lt500r clutch won't disengage  (Read 957 times)

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87 Lt500r clutch won't disengage
« on: January 02, 2016, 04:31:48 pm »
I have a 87 500 and I have to pull in clutch lever, in neutral, so it will roll freely. It acts like it's in gear but it's not. Anyone have this problem before? Could it be the basket is grooved?
Thanks for any help or opinions. Appreciate it and happy New year!!
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Re: 87 Lt500r clutch won't disengage
« Reply #1 on: January 02, 2016, 09:46:31 pm »
Could be simple like clutch cable adjustment   
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Re: 87 Lt500r clutch won't disengage
« Reply #2 on: January 03, 2016, 02:31:10 am »
a grooved basket might allow the plates to stick together, as would cold, thick, or dirty spent oil. you can try to run a file on the basket if its not too bad but you run the risk of having part of the basket shoot out of the case. 
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Re: 87 Lt500r clutch won't disengage
« Reply #3 on: January 03, 2016, 09:00:24 am »
It's best to use the search function, most usual problems have already been addressed, some times multiple times.

http://www.suzukiquadracerhq.com/engine-13/wont-shift-into-neutral/msg47560/#msg47560

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Re: 87 Lt500r clutch won't disengage
« Reply #4 on: January 04, 2016, 11:10:19 am »
I tried the search engine, couldn't find anything.
The circlip was off the idle gear, hence the noise I was hearing, lol.  I guess I'll order new oem basket and plates with springs and bearing too. Basket is grooved. I guess oem is the only option? Idk.
Thanks for the input, I really appreciate it. Never monkied with a clutch before.
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Re: 87 Lt500r clutch won't disengage
« Reply #5 on: January 04, 2016, 09:29:08 pm »
The spacer (part #   09180-22021) the clutch bearing runs against will sometimes get crushed from over torquing the nut that holds the inner clutch hub onto the transmission shaft.  Putting/making a .010 to .020 shim under the spacer to make it effectively longer is added insurance to prevent the clutch from binding .  When this sleeve is too short it will make the clutch continue to transmit some power when the clutch plates are disengaged. 
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Re: 87 Lt500r clutch won't disengage
« Reply #6 on: January 05, 2016, 05:53:00 am »
Thank you motor geek. Appreciate the insight.
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Re: 87 Lt500r clutch won't disengage
« Reply #7 on: January 07, 2016, 04:47:40 am »
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Re: 87 Lt500r clutch won't disengage
« Reply #8 on: January 07, 2016, 02:45:54 pm »
Here is the shim you need, this one is .030 (30 thousandths), they make other thicknesses (.020/.040)
https://www.fastenal.com/products/details/7041862?r=~|categoryl1:%22603582%20Power%20Transmission%209and%20Motors%22|~%20~|categoryl2:%22600943%20Shims%209and%20Shim%20Stock%22|~%20~|categoryl3:%22604633%20Arbor%20Shims%22|~%20~|sattr03:^0.003%22$|~%20~|sattr02:^1-1/8%22$|~


Get one that fits the OD and one as close as you can on the ID then dremmel it out on the inside to fit.

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Re: 87 Lt500r clutch won't disengage
« Reply #9 on: January 16, 2016, 07:33:50 am »
Ok. I replaced the clutch basket, pressure plate, primary drive gear, plates ect... I believe it's going into neutral and won't roll. I pull the clutch in, it'll roll. Haven't started it yet, I know something's not right. I did not install a spacer/shim as motorgeek suggested because the oem spacer appeared to be ok. If I take the cover off, is there something I should look for to trouble shoot my problem? Any help is greatly appreciated. Thank you
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Re: 87 Lt500r clutch won't disengage
« Reply #10 on: January 16, 2016, 09:50:38 am »
I pulled clutch cover and removed plates. I put it in neutral and when I spin the tires, the inner basket/clutch shaft spins. Is that normal? I would think it wouldn't.
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