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October 23rd, 2015, 01:06 PM   #1
Joined: Feb 2014
From: Seattle, WA

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I Ride: 2005 FE550
Clutch lever stuck after removing clutch

Hi guys and gals,

I have a 05 FE550 and was doing the water pump seal when I managed to dislocate the kickstarter mechanism. Fixed that no problem by removing and re-installing the clutch, but now my clutch lever is pretty much stuck. I have a Rekluse Z-Start Pro btw, and pretty sure I reassembled everything correctly.

My guess is that the slave cylinder plunger or something is out of place or jammed. I haven't bled or touched the clutch hydraulic circuit yet.

Thoughts on how to attack this one?

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October 24th, 2015, 12:11 AM   #2
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sometimes the lever can come so far out that the pin is dislocated.

look up at the bars first?

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October 24th, 2015, 07:28 AM   #3
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I Ride: 2 2005 FS650C; 2 2004 FS450C; 1993 Honda F2; 1972 Triumph Daytona; 1969 Ducati 450 Jupiter; 1974 rd
Originally Posted by Taffy View Post
sometimes the lever can come so far out that the pin is dislocated.

look up at the bars first?

My thought too. Sounds like something simple just became misaligned. Check the cable end inside the lever, the cable, the adjusters and work your way back to the slave cylinder. Make sure the lever sleeves (I'm sure there's a correct name for these things - dowel?) that allow you to tighten the screws holding the levers on your bike are in place too. I know it's silly, but check that you didn't over-tighten something. I generally loosing everything up a little bit to allow for alignment and adjustment all along the system.
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clutch, lever, removing, stuck

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