XT 600 E clutch won't disengage
 

Sorry to be asking for help yet again but I cannot figure out where I have gone wrong with the clutch reassembly on my 1997 XT. It freewheels fine in neutral but when in gear it does not disengage when I pull in the clutch. I've tightened the cable to the point where the clutch slips without me even touching the lever. When I pull it in at this point it makes no difference at all. So far I have:

- pulled off the crank case cover again to check I have put the clutch plates back in the right order
- double checked that the arrow on the pressure plate lines up with the marking on the clutch basket
- made sure the teeth on the clutch lever are engaged with the push rod
- run the bike for five minutes to warm and thin the oil

I've searched the forum for answers without success and have now run out of ideas. I'm sure it's some stupid oversight on my part but can't work out where. If anyone has any advice I would be very grateful.

You have those 2 larger id fiber discs in there proper spot ? Mainly the last one so it fits over the shoulder on the clutch inner hub cover(pressure plate) ? You have the cushion spring that goes inside the other "special" disc , 2nd disc installed ?

If yours has the lever that goes into the clutch cover on the right side of motor , there is a certain position it needs to be turned to as you install the cover so when the cable pulls it there is enough travel to fully disengage the clutch (most likely issue your having ) .

If your motor has the lever underneath the starter toward the left side of motor , is the steel ball there ? is the adjuster bolts properly adjusted before putting the cover on ?

Thanks for the response jjrider. Mine has the lever on the right side which I am pretty sure has engaged with the push rod as it has a definite arc of movement and stop point. I've have tried lifting the lever arm off and rotating it further back to give more range of movement but that doesn't seem to make a difference.

I didn't realise that the last plate is also different (I got the second one installed ok) but as they went back on in the same order they came off I think (hope) I got it right. Looks like I'll be taking the cover off again. Guess there'll be no saving the gasket this time :-)

I had one other thought. Do you think it would make a difference to get the engine hot again and then pull the clutch lever a few times to see if the plates will throw off any friction between them?

Problem solved
 

I figured out what the problem was so thought I would post it here in case any other newbie like myself is in the same situation.

The clutch would not disengage with the bike in gear and the engine off so I got it up on a block to get the back wheel off the ground and got a mate to help me hold it steady. Then I started it in neutral, kicked it into first and levered the clutch half a dozen times until it started to disengage. Then I took it out for a quick ride and tested it again when I got back. Everything disengages beautifully now.

I think the problem might have been that I had the clutch plates out of oil for ten days or so so maybe they dried out. I'm just relieved that I didn't have to take the cover off again.

Well done for sorting it.Don't know if you did this,but again it might help others... soak all new plates in engine oil prior to assembly..

I've had a few bikes and atv's that when they've sat for a couple weeks , the first time shifting into gear could be interesting . Most were like that when I bought them but after changing the oil to what I run , most have quit doing it . An XL600 I bought we couldn't get it to disengage , choked the motor off 4-5 times, pushed it back and forth in high gear ect.. took 1/2hr of rocking in the back of my truck for it to finally break loose(left it in gear for the trip home), worked fine once home. 4 days later it took 2 motor choke-offs to break loose again, but it completely quite after new oil was installed.

Only had 1 660 Raptor I bought brand new , clutch always stuck after sitting for 2-3 weeks , would need to hold all brakes and pop the clutch or several rocking back-n- forth, did it yet the day I sold it with 8k miles on it. This was before I started using a certain oil though. Moral of the story , be prepared for it to be stuck possibly next time it sits , usually it'll go away.
If it does try a different oil once to see if it helps.