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06 rmz450 very hard to find neutral

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Before dislocating my shoulder on Thursday (that's what i get for trying to keep up with guys much better then myself) it was super hard to find neutral- running or not. Usually it'd easier to go from 2nd but nothing near what it should be. I've read it's worn clutch baskets but maybe it's something deeper... Any ideas?

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Well it looks like the previous owner forgot to install the wave washer and seat. It's probably causing the clutch to slightly engage making neutral harder to find. 

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Gotta love used bikes! For your sake, I'm glad it was just a washer. The 4 speed trans in the 05-07 is about as bulletproof as you can get.

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It should actually get better with the judder spring (wavy washer) removed. The only thing that spring does is cut down on clutch noise. I would bet your first assumption will lead you to the answer you are looking for. You need a new clutch pack. Measure it and see if it is still in spec. Most of the aftermarket clutch systems ditch it for a reason. The spring does nothing but create drag.

Edited by BDubb106
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I also have the problem of finding neutral on the 06 I recently purchased. Finding it is difficult and I have found I just barely need to touch the shift lever to get to neutral.

On 5/11/2017 at 6:49 AM, BDubb106 said:

It should actually get better with the judder spring (wavy washer) removed. The only thing that spring does is cut down on clutch noise. I would bet your first assumption will lead you to the answer you are looking for. You need a new clutch pack. Measure it and see if it is still in spec. Most of the aftermarket clutch systems ditch it for a reason. The spring does nothing but create drag.

So is taking the wavy washer out going to help me? If so where is it located? I can take a look next time I go to do an oil change.

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4 hours ago, TwistedRutt said:

I also have the problem of finding neutral on the 06 I recently purchased. Finding it is difficult and I have found I just barely need to touch the shift lever  to get to neutral.

So is taking the wavy washer out going to help me? If so where is it located? I can take a look next time I go to do an oil change.

It may... but not if parts of the clutch are worn past spec or anything is warped. Part # 12-13 in the parts fiche, under the clutch pack. Lots of RMZ owners no longer running them. 

https://www.thumpertalk.com/shop/oem.php?partcategory=778385&manufacturer=5&category=5&year=2006&model=27201

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On 5/11/2017 at 3:49 AM, BDubb106 said:

It should actually get better with the judder spring (wavy washer) removed. The only thing that spring does is cut down on clutch noise. I would bet your first assumption will lead you to the answer you are looking for. You need a new clutch pack. Measure it and see if it is still in spec. Most of the aftermarket clutch systems ditch it for a reason. The spring does nothing but create drag.

I just put in a new a new clutch pack and I've got a new inner clutch basket waiting to go in as well. The outer was typical worn and I did the file trick until I absolutely need to replace. Thanks for the input again! 

Edited by Jon Broadbent
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My 06 is about the same, it's seems to be common with 05-07, it was complained about in Motocross actions review in 06. It's a bug but I can tolerate it. 

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