Hey everyone,
I’m new to the forum and decided to post here after hitting a wall with a clutch issue on my 2007 R1. I recently rebuilt the motor (bike was bought with a rod through the case) as a fun project. The engine runs great now, but the clutch won’t disengage when I pull in the lever.
Here’s what’s happening:
When I start the bike and put it into gear, it stalls unless I give it throttle and dump the clutch. The clutch lever has normal resistance and actuates the pressure plate — I’ve confirmed movement through the oil fill hole — but the clutch plates are still engaging.
What I’ve done so far:
Any advice would be hugely appreciated!
Here are also 2 youtube videos I uploaded to give you guys more of idea of whats going on.
I’m new to the forum and decided to post here after hitting a wall with a clutch issue on my 2007 R1. I recently rebuilt the motor (bike was bought with a rod through the case) as a fun project. The engine runs great now, but the clutch won’t disengage when I pull in the lever.
Here’s what’s happening:
When I start the bike and put it into gear, it stalls unless I give it throttle and dump the clutch. The clutch lever has normal resistance and actuates the pressure plate — I’ve confirmed movement through the oil fill hole — but the clutch plates are still engaging.
What I’ve done so far:
- Disassembled and reassembled the clutch over 50 times, going past the basket to double-check everything.
- Verified the correct order of components:
- Thrust washer
- Oil pump gear, sleeve, and bearing
- Clutch basket with washer and second thrust washer
- Clutch boss assembly
- 3 clutch springs and 30mm nut torqued to spec
- Plate order:
- Flat metal ring
- Conical spring
- Small clutch plate
- Steel/friction stack (last friction plate offset half-phase to the right)
- Pressure plate torqued to spec with housing splines aligned properly
- Clutch stack height: 42.5mm (well within spec)
- Friction plates soaked in oil for 24 hours before installation and generously oiled during assembly
- Tried the “lever zip-tied overnight” trick to break the plates loose
- Plates and steels are in great shape — no noticeable wear or warping
Any advice would be hugely appreciated!
Here are also 2 youtube videos I uploaded to give you guys more of idea of whats going on.
