SuzukiSavage.com - Print Page

SuzukiSavage.com
/cgi-bin/YaBB.pl
General Category >> Rubber Side Down! >> Clutch problem
/cgi-bin/YaBB.pl?num=1136171318

Message started by Jim_R on 01/01/06 at 19:08:38

Title: Clutch problem
Post by Jim_R on 01/01/06 at 19:08:38

So I was driving my bike and lah de dah. WHAM! No clutch. I was like uh D@MN! No tension on the lever so I made it to my friends house. We thought it might be the cable but nooooo.. that would be too easy.

After a quick call to Torque's tow truck service and garage we discovered it was a CAM,CKYTCG RELEASE.
It was broken clean in half. We removed the 4 bolts and inspected the springs and clutch. They looked fine and thank god its only a 5.00 part.

Anyone else had this happen to them?

Title: Re: Clutch problem
Post by bentwheel on 01/01/06 at 20:19:23

Jim_R wrote:

it was a CAM,CKYTCG RELEASE.

Heck, I'd have thought it was a BRIIYPTAQP.

Title: Re: Clutch problem
Post by Greg_650 on 01/02/06 at 07:41:16

Oh. You mean the #%^&*&@(@(*&$! Cam Release?

Why?

Title: Re: Clutch problem
Post by Jim_R on 01/02/06 at 07:56:44

http://www.geocities.com/jimruggiero/clutch2.jpg

Ok its the part number 24. I have no clue why it broke. My bike is 10 years old. Maybe stress caught up with it.

Title: Re: Clutch problem
Post by Greg_650 on 01/02/06 at 08:03:04

I would be checking to see that #23 was freely floating in the hole and that the clutch basket releases as it should before I put it back together.

Did you notice the clutch becoming more difficult to operate before it broke?

Photos of the broken piece?

Title: Re: Clutch problem
Post by torque on 01/02/06 at 08:17:10

the pin is moving freely,and the clutch is fine,the cam release broke at its weekest points.

Title: Re: Clutch problem
Post by Greg_650 on 01/02/06 at 09:16:12

torque wrote:

the pin is moving freely,and the clutch is fine,the cam release broke at its weekest points.

#20 slides freely?

Title: Re: Clutch problem
Post by Digger on 01/02/06 at 09:18:10

Take a look at the cam under a magnifying glass. When a part breaks like this, you can frequently see evidence of a crack that has been propagating slowly with time. You can sometimes see signs of corrosion on the crack surface, which means that the crack started some time ago.

Interesting stuff.

JIM,

How many miles on the bike?

Title: Re: Clutch problem
Post by torque on 01/02/06 at 09:36:09

Greg_650 wrote:

#20 slides freely?

23 slides freely,20 does not(which is a good thing)

i think theres around 9,000 miles on his,if the previous owner didnt play with odometer ::)

Title: Re: Clutch problem
Post by Greg_650 on 01/02/06 at 10:48:11

torque wrote:

23 slides freely,20 does not(which is a good thing)

Oops, I meant #23 slides in #20, freely.

It almost seems like #29 would have broken first.

Title: Re: Clutch problem
Post by torque on 01/02/06 at 10:58:46

#29 cant really "brake" it just a cotter pin,that holds #25 in place theres never any pressure on it.

after looking at my #24 im going to get a new one, while i have it apart .theres a hell of lot of pressure on such a weak part.

Title: Re: Clutch problem
Post by Greg_650 on 01/02/06 at 11:43:55

torque wrote:

Since the cam is located by the flat on the shaft, the cotter pin is probably intended to shear first. Maybe, maybe not. As Digger said, there must have been fatigue developing in the cam.

Either way, Jim gets a First Time Award for clutch breakage. I don't think we've heard of this before.

Title: Re: Clutch problem
Post by torque on 01/02/06 at 13:24:55

greg ,i think u think that the lever arm slides into the rod with the flat end and the cotter pin holds them together...this is not the case.the "L" shape #25 is one piece,with a little hole drilled in it,that the cotter pin goes into to keep the arm from sliding out of the side cover ;) #28 is a o-ring

Title: Re: Clutch problem
Post by Greg_650 on 01/02/06 at 13:55:09

Yes, I know. I've had it apart, but maybe I'm a little rusty. There are flats on the shaft for the #24. Isn't #27 a snap ring and #26 a spring?

Title: Re: Clutch problem
Post by torque on 01/02/06 at 13:59:11

#27 is just a washer,#26 is a spring

Title: Re: Clutch problem
Post by Jim_R on 01/02/06 at 15:47:59

I think my bike is possessed. I wonder if the original owner died. :o

We have put so much work into the bike and my clutch breaks without any warning.. I know its kinda old 95 but its not high milage.

So far lets see.. the clutch thingy broke, the cam chain broke and bent the valves via piston. it has ditched 2 battery covers, broke a fork seal (before I got it).
I wonder whats next??? only time will tell.

Title: Re: Clutch problem
Post by Greg_650 on 01/06/06 at 11:10:01

I'm about to take my bike apart over this :P

What is the purpose of the flats on the shaft, #28?

Why are there flats in the hole of the cam, #24?

If #27 is just a washer, what holds the darn thing, #24, on the shaft?

http://i21.photobucket.com/albums/b277/gmdinusa/clutch3.jpg

Title: Re: Clutch problem
Post by torque on 01/06/06 at 12:33:44

the shaft slides into a hole that is part of the crank case cover.

the shaft has to be flat just like the inside of the cam,just like male,female adapters.the cam depresses the clutch.

Title: Re: Clutch problem
Post by Greg_650 on 01/06/06 at 13:15:22

torque wrote:

the shaft slides into a hole that is part of the crank case cover.

the shaft has to be flat just like the inside of the cam,just like male,female adapters.the cam depresses the clutch.

I got all that. I've had mine out, but maybe I've had a brain fart.

My questions are...

What is the cotter pin, #29, holding together? The outside clutch arm and the actuator shaft, right? #29 to #25?

What does the washer, #27, do?

Maybe I remember...Does the end of the shaft, #29, fit into something else inside the case with the washer in between?

Title: Re: Clutch problem
Post by torque on 01/06/06 at 13:52:28

Greg_650 wrote:

the end of the shaft fits into a protrusion sticking out from the case,(the protrusion is part of the solid case)

the washer is there just as spacer and a form of antifriction,between the cam and case protrusion.

the cotter pin holds the shaft from sliding out of the case.the cable lever and the shaft are one solid piece.
in other words go to your bike and try to pull the cable lever/shaft out of thr engine case,it won't come out,because the cotter pin is on the inside of the case,and through the shaft .

Title: Re: Clutch problem
Post by Greg_650 on 01/06/06 at 14:25:46

torque wrote:

Okay. Now I got it, or I remember. Not 2 pieces. Thanks. I was just trying to clarify my earlier comment about the cotter pin shearing off...but now I see that ain't so.

So, Jim just had bad luck and the cam broke. The good side is that the broken piece didn't get into the primary gears or the oil pump drive.

I'll shut up now :P

Title: Re: Clutch problem
Post by torque on 01/06/06 at 15:00:31

Greg_650 wrote:

So, Jim just had bad luck and the cam broke. The good side is that the broken piece didn't get into the primary gears or the oil pump drive.

yeah he is really lucky,that it didnt fall into the gears,that would have been one mell of a hess

Title: Re: Clutch problem
Post by Greg_650 on 01/06/06 at 15:05:39

He also did the smart thing to stop. Me? I know that I'd have gotten it rolling in first and tried to jerk back home without the clutch....just the time that piece might need to really mess it up....He's lucky to have a Friendly Savage Towing Service close by.

Title: Re: Clutch problem
Post by Jim_R on 01/06/06 at 15:53:44

Yeah as well as a super motorcycle mechanic like Torque and his dad's tools and ingenuity. So I guess I am lucky in some strange way. I'm def glad I didnt have to get a new clutch. My bike might be fighting its restoration but I wont give up until she is done.

Oh when the clutch gave out and I came to a stop I thought about it for a second. I turned the bike off and went into neutral. Started it up and gave it a little gas and shifted into 1st. I almost flipped. Then I tried to shift into neutral and shift into 2nd. It stalled.

So I said bump this and started it into 2nd gear and chug chug chug (fart) away I go. Super rough but no dangerous wheelies hahaha.