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Message started by residualsilver28 on 06/14/12 at 08:10:03

Title: clutch issue
Post by residualsilver28 on 06/14/12 at 08:10:03

okay little background. so bought a 02 in march from a place called road track and trail, she ran kind of crummy till week before memorial weekend when it died at a stop light. Did some digging when I found this AWESOME website! thank you all for your knowledge. Saw that my oil window was pitch black. With beginner skills at repair, that weekend I pulled the tank off did a raptor, added a fuel filter, cleaned out the carb (Mikuni), air filter box and filter. dumped out the 2qrts oil and 3 qrts gas, replaced with 5-w40 (after reading the coin tossing with oil wights discussion). Had to do it twice forgot the first time to turn off the pet, gas all over the place. >:( ...
Now she is running like a champ :D popping and crackling along like she should and while out bumming round two weeks ago I pulling up to a stop light shifted into N and she would NOT go into 1st and will tap into 2nd but won't sit in 2nd. found that if I rev it a little, it will go into 2nd but will still not go into first. This happens at randomly now. I'm not beating the heck out of the bike either. anyone have any idea what i should look at doing first?

Title: Re: clutch issue
Post by verslagen1 on 06/14/12 at 08:26:52

clutch cable tight enough?

arm between the marks?

Title: Re: clutch issue
Post by justin_o_guy2 on 06/14/12 at 08:39:09

How much can you move the clutch lever with your pinky?

Have you been stomping the shifter to get in first sitting still, in neutral, with clutch pulled?

Title: Re: clutch issue
Post by residualsilver28 on 06/14/12 at 08:50:55

I can pull the lever about half way with my pinky but there is resistance all the way. there is not much thread left at the end of the cable cover thing. its loosly in there too. Ill tighten that.
No i don't have to stomp on it to get it in on a regular basis or sitting still. its a nice hard click/clunk when it goes.

Title: Re: clutch issue
Post by verslagen1 on 06/14/12 at 09:08:44

should be between the mark just pulling hard enough to take up the slack

http://www.hunt101.com/data/500/medium/Short_rod1.JPG

Title: Re: clutch issue
Post by residualsilver28 on 06/14/12 at 09:16:13

resting it is even with the top mark... should i lower it so it is in the middle?

Title: Re: clutch issue
Post by verslagen1 on 06/14/12 at 09:20:01

middle range would be better, here's the thread...

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1270678838/30

Title: Re: clutch issue
Post by justin_o_guy2 on 06/14/12 at 09:27:27

3423352F2233272A352F2A302334747E460 wrote:

M aybe I should have been more careful, not all pinkies are created equal. I knew a guy who could do pullups with his pinkies & he weighed 180 to 200 pounds,,
How far can ya move the lever without moving the actuator on the motor? If its more than 1/4 inch, the cable is too loose. The answer to that could be in the adjustment on the handlebar or down on the motor or the rod inside or a combo.

Title: Re: clutch issue
Post by residualsilver28 on 06/14/12 at 10:04:43

im going to adjust the cable down so it sits in the middle and see if that works. if not ill try the next thing..

Title: Re: clutch issue
Post by justin_o_guy2 on 06/14/12 at 10:33:35

There has to be some slack in the cable, always,

Title: Re: clutch issue
Post by Cavi Mike on 06/14/12 at 11:54:26

6671677D70617578677D78627166262C140 wrote:

im going to adjust the cable down so it sits in the middle and see if that works. if not ill try the next thing..

Adjusting the cable doesn't adjust your clutch, it only adjusts cable slack and the position of the lever when the clutch engages/disengages.

Title: Re: clutch issue
Post by 360k+ on 06/14/12 at 20:52:51

Too much play = possible residual clutch engagement

Too little play = possible non release of clutch (and possible slippage)

If 1st (or any) gear offers resistance, lighten clutch lever a bit while pressing shifter to allow the gear dogs to find their holes.

Title: Re: clutch issue
Post by residualsilver28 on 06/16/12 at 07:23:20

i was playing with it a little yesterday and will give another attempt today. If i loosen it enough to sit between the marks then its so loose that clutch lever goes limp(that reads really wrong). maybe I'm just retarded lol :-/. maybe ill put some weights the end so it goes back down... after reading the above linked discussion sounds like I may need a longer rod?

Title: Re: clutch issue
Post by verslagen1 on 06/16/12 at 14:57:47

627563797465717C63797C6675622228100 wrote:

No, you don't adjust the cable till it's in between ($%@#!) adjust the cable to remove all but an 1/8" at the lever and if the arm isn't between you gotta replace the rod.

It's usually the opposite of what you think, dam tricky adjustment.
So if you buy a new rod, don't just buy one, buy them all especially if you don't know which one you got.

Title: Re: clutch issue
Post by residualsilver28 on 06/16/12 at 16:32:44

2D3E2928373A3C3E356A5B0 wrote:

[quote author=627563797465717C63797C6675622228100 link=1339686604/0#12 date=1339856600
It's usually the opposite of what you think, dam tricky adjustment.
So if you buy a new rod, don't just buy one, buy them all especially if you don't know which one you got.

Do i buy them from a dealer, ebay or someplace else? it looks like a kinda easy diy job. if i ask for all three lengths will they know what I'm talking about or will they give me a the deer in the headlights look?

Title: Re: clutch issue
Post by verslagen1 on 06/16/12 at 16:55:21

oem parts dealer will have them, it's in the fish

You can diy, but you need rock hard dowel pins, not drill rod.