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Message started by Jonny_Chicago on 06/09/08 at 09:58:23

Title: Torque Specs?
Post by Jonny_Chicago on 06/09/08 at 09:58:23

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Ok, so I was riding the savage the other day and bout 45 minutes from my house the clutch gives out (I was unable to engage the clutch). I had to shift back home without a clutch! (this is not the first time clutch cable has gone; on the expressway in Chicago, the cable broke! now that was scary!)

Anyway, when I got home I noticed the clutch cable was NOT broken. The clutch lifted the lever that goes into the engine like it is suppose. However, there was free play when I pulled the clutch down. There was no tension. I blew every stop sign and red light to get home, so I didnt have to down shift without a clutch.

Any suggestions as what could be wrong? Transmission? I have a feeling this is going to be more expensive to fix than a broken clutch cable :'(

Any input is much appreciated :)

Thank you for taking the time to read my problem :)

Thanks again
Jonny

P.S. If I was not clear on anything let me know

Thanks again!

Title: Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?!
Post by verslagen1 on 06/09/08 at 10:06:29

I believe there is a pin that connect the exterior lever and shaft to a cam on the inside of the clutch cover. It could be sheared.

Title: Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?!
Post by Jonny_Chicago on 06/09/08 at 10:09:43

If I take the clutch cover off is there oil in there?

Title: Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?!
Post by youzguyz on 06/09/08 at 10:17:20

Yep, sure is. Best bet is to drain the oil. 2nd best bet is to lean bike WAY over/
Be very, very, careful, and you might be able to salvage the clutch cover gasket for re-use.

Title: Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?!
Post by youzguyz on 06/09/08 at 10:20:14

Here is the pieces:
Clutch Parts (http://fiche.ronayers.com/Index.cfm/Module/Main/TypeID/26/Type/Motorcycle/MakeID/2/Make/Suzuki/YearID/43/Year/2002/ModelID/6838/Model/LS650P_SAVAGE/GroupID/291983/Group/CLUTCH)
The pin verslagen is talking about is #22

Title: Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?!
Post by Max_Morley on 06/09/08 at 18:01:24

The part that broke on me is 21 the clutch cam. It is just a cast piece and broke in two pieces. Max

Title: Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?!
Post by verslagen1 on 06/09/08 at 20:16:52

I've done the lean over trick, it works.

Title: Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?!
Post by Jonny_Chicago on 06/10/08 at 10:35:55

What's the difference between the three different kinds of #22 in that diagram?

Title: Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?!
Post by verslagen1 on 06/10/08 at 11:14:34

did you take it apart yet?

As to what part #... 28 not 22.

Don't really know, but would assume years

Title: Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?!
Post by youzguyz on 06/10/08 at 11:30:28

382B3C3D222F292B207F4E0 wrote:

did you take it apart yet?

As to what part #... 28 not 22.

Don't really know, but would assume years

My mistake.. I thought verslagen meant the push pin (#22), not that cotter pin (#28).

Title: Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?!
Post by Jonny_Chicago on 06/10/08 at 18:39:48

Ok, I have not taken it apart yet. Just ordered the parts. Thanks all for the useful help!

Thanks again. I will keep you guys posted on updates!
:)

Title: Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?!
Post by verslagen1 on 06/10/08 at 18:54:52

if you haven't taken it apart, how'd you know what needs fixin?

Title: Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?!
Post by Jonny_Chicago on 06/11/08 at 00:36:14

Guessed? Plus you guys gave me some input on the problem. Hoping it is not more than just the pin. Plus the cotter pin is only $.68. If it is more of a headache I will be crawling back to ask more questions. I will keep you guys posted.

Thanks again!

Title: Re: UPDATE, PLEASE HELP; Its the release cam.
Post by Jonny_Chicago on 06/16/08 at 19:19:10

Well, I guessed wrong. When I got the case off it turned out to be the Release Cam in the Clutch Assembly (#5). It was broke in two. I guess thats my fault for driving it like I stole it a.k.a. driving like sh*t.

Do you guys know what torque spec to set on the bolts?

Also, any further advice at all is much appreciated!

Thanks again, you guys are great! :)

Jonny

Title: Re: Torque Specs?
Post by Jonny_Chicago on 06/17/08 at 10:52:44

P.S. Thought I would use this same topic so I didnt have to start a new one.

Title: Re: Torque Specs?
Post by youzguyz on 06/17/08 at 12:16:14

I assume you mean the clutch cover bolts. I know you kept track of which one goes where.. right?
Anyway, as far as I know, there isn't a specific torque for those bolts.. at least I haven't been able to find it in the cryptic tables posted here or in my Clymers.
If someone knows different for sure, please say so!! :D

Title: Re: Torque Specs?
Post by verslagen1 on 06/17/08 at 13:38:16

The torque on the clutch cover is low like everywhere else.

Off the top of my head 8 ftlbs, or as much as you can torque one handed with your hand as close to the socket as posible. I use an allen wrench myself. ;D