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A buddy & I jus got done rebuilding his 02 1K. When starts and when in neutral its fine, but when u put the bike in first gear with the clutch pulled in the bike wants to move forward? Tried adjusting the clutch at the lever and still nothing. Any ideas? Seems like the clutch is not disengaging all the way when the lever is pulled in.
 

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is this a new clutch? do you have any play in the clutch lever? if you have a lot try to adjust the cable from where it goes into the motor...i had a problem like that it was the clutch stack height
 

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sounds like you need to adjust the clutch at the little screw on the sprocket cover side.
 

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First make sure clutch cable is free,not kinked or bound up.Second,screw the adjustment by the clutch handle all the way in.Third, remove center cover of clutch cover. Fourth, hold the big back nut with a 12mm,and the front lock nut with a 10mm.Fifth, unlock it.You need to then back out the inner screw allowing about 1/8inch to 1/4 inch worth of slack.Tighten it all back down and make sure you still have slop.Put cover back on and then tighten the adjustment knob by the clucth leaving at least 1/2 inch worth of slack.More slack is better than not enough.Don't hot lap,adjust lever every 3 to 4 passes,and when adjustment on lever goes away, re adjust on the bottom again.:2thumbs:
 

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I take it he oiled the fibres before assembly, if so it's just the oil in the plates that are making them "glue" together, pretty normal. It should spin out with a bit of RPM / a spin around the block.

E
 
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