1990 RM125 Rebuild & Clutch questions

[suzukimxrider]

So I posted about a month or so ago asking about the basics of rebuilding my bike, and now I'm done (woohoo!)

First question; after a top-end rebuild, is it going to take a lot of kicking for it to kick over and start? Unfortunately there are no hills near me, so compression starting isn't as easy. Gas is flowing to the carb, and the plug is sparking - My only thing is I'm not too sure if gas is flowing to the plug. When the bike was apart, everything was cleaned, and reassembled properly, I also didn't take anything apart that didn't need to be taken apart (all that was done was a top end)

NOW

This brings me to my clutch question. I'm already assuming the answer is going to be "rebuild the clutch" but I'm going to ask anyways. I can't compression start the bike because the clutch is stuck closed. The clutch lever freely moves back and forth, and does not snap back as supposed to. Also, the spindle thing that the clutch cable connects to on the motor itself, can turn a few degrees (as it should) by hand, and it's quite easy. I've had my clutch get stuck before, but it was from someone putting the wrong transmission oil into it. Also note that the bike hasn't been ridden in about 4 years, but this problem developed AFTER the bike was re-assembled, the clutch was all fine before we took it apart.

The engine sat drained for 3-4 weeks (parts shipping, and free time) so I can assume the plates are stuck, or the spring is stuck in either it's open or closed position.

Your thoughts, ideas, and comments are appreciated. I read the manual in taking the thing apart, followed it's directions and am now scratching my head. Thanks!


Robert

[Spikester]

Sounds like you may have put the clutch cover on wrong, the clutch is operated by a rack and pinion type of actuator, the teeth on the shaft and the pinion have to line up correctly to work. Look at this link and find your model and look at the parts. Plates can stick together, should come un-stuck when it is started or you can take them out if you check the clutch out. If the carb is gummed up it won't run, take the jets out and blow carb cleaner thru them ALL and clean out all the passages, use compressed air too. If it hasn't been run in a while (4 years) it WILL need it.


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[suzukimxrider]

yeah the clamp thing that goes on the clutch spindle was put on backwards, so that was a quick and easy fix. We took the carb apart again, and one of the floats had gotten stuck in the up position, so it cut off fuel flow. Lubing it up fixed the problem, and it started up in 4 kicks! After letting it warm up, I did a test ride down my street, I forgot how much power this thing had!