New twist on this error message as this just happened to me. I thought I would pass this along for troubleshooting in case it happens to someone else. Searches on this error brought up topics that were not what happened in my case.
Got the error message after a long print with quite a few filament changes. The printer stops and will not proceed. I checked the lever and it moved freely. Very freely. Not stuck at all. I pulled off the front toolhead cover and with a quick glance, it all looked fine. So I replaced the cutter blade thinking it’s probably time anyway and it’s a quick easy maintenance thing to do. The printer still threw the “cutter lever stuck” code.
Cover off again to check all of the plug in’s on the tool head. A wire caught my eye. Not a plugin but a disconnected wire from a soldered spot on the extruder filament sensor. Specifically, the white wire. Follow the ribbon cable from left to right.
What I think happened was the cutter lever, through vibrations & movement, was possibly hitting the sensor area or close to it, eventually causing the white wire to wiggle enough to break loose. Printer has about 4600 hours on it, original extruder. There was a slight bit of “slack” in the ribbon cable allowing it to move left towards the cutter.
Pulled out a spare extruder and installed. Problem gone. I paid special attention on the ribbon cable routing and stuck a small piece of double-faced tape to further secure the ribbon cable to the extruder. Ordered a new extruder filament sensor for 12 bucks, cheap fix if it should go bad again.
