SuzukiSavage.com /cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Clutch issue... /cgi-bin/YaBB.pl?num=1367921494 Message started by Smokestack on 05/07/13 at 03:11:34

Title: Clutch issue... Post by Smokestack on 05/07/13 at 03:11:34 Hey all.  So I finished my top end rebuild (new cam chain and guides, big jug, camshaft) and am really pleased with the way she runs with one exception.  The Clutch is acting....weird.  The shift lever doesn't return properly after shifting up (down is fine), and I have to tap it back into place before the next gear.  Also, after it heats up, I seem to be getting a false neutral light; as in the neutral light on the dash is green, but its still in gear when I release the clutch and so she jumps and stalls.  It is also a lot harder to get that neutral light (and into neutral period) on shut down than before.  It hasn't slipped while running in any discernable way, so I'm stumped. When I removed the clutch basket to install the cam chain and guides, I ran a bit of wire through the center of the assembly so I wouldn't mix anything up on re-installation, but it's possible I got something backwards.  Maybe the thrust washers? Any ideas?  I'm going to check the clutch arm position to the case marks tonight after work, but any other suggestions would be helpful.

Title: Re: Clutch issue... Post by Oldfeller on 05/07/13 at 07:22:47 IF you screwed up the washers in back of the basket, you couldn't put the little pin back in place correctly. IF you didn't put the little pin back in place, you run a strong risk of disconnecting the oil pump drive gear and killing your engine due to lack of lube oil pressure. Do you remember seating the little horizontal steel pin in the stack of washers behind the clutch basket?

Title: Re: Clutch issue... Post by justin_o_guy2 on 05/07/13 at 09:27:46 It is SO easy to put that gear on bakkerds,,,

Title: Re: Clutch issue... Post by paulmarshall on 05/07/13 at 12:28:39 734D4F4B45535441434B200 wrote: Hey all.  So I finished my top end rebuild (new cam chain and guides, big jug, camshaft) and am really pleased with the way she runs with one exception.  The Clutch is acting....weird.  The shift lever doesn't return properly after shifting up (down is fine), and I have to tap it back into place before the next gear.  Also, after it heats up, I seem to be getting a false neutral light; as in the neutral light on the dash is green, but its still in gear when I release the clutch and so she jumps and stalls.  It is also a lot harder to get that neutral light (and into neutral period) on shut down than before.  It hasn't slipped while running in any discernable way, so I'm stumped. When I removed the clutch basket to install the cam chain and guides, I ran a bit of wire through the center of the assembly so I wouldn't mix anything up on re-installation, but it's possible I got something backwards.  Maybe the thrust washers? Any ideas?  I'm going to check the clutch arm position to the case marks tonight after work, but any other suggestions would be helpful. What size piston did you use? What stage cam shaft? How many miles on new motor?

Title: Re: Clutch issue... Post by Smokestack on 05/07/13 at 17:02:44 Oldfeller; I'm pretty sure I seated the pin, but since I'm going to pop the cover anyway, I'll double check. JOG; I'll double check that gear too... Paul; It's a 96mm with stage 3.  It was the first drive home, so less than 15km on the motor. Also, looking at the Clymers, what about the external shifter linkage springs?  I'm thinking of the ones under that little case just below the drive sprocket.  The shifter return spring being bent or broken on the upshift side would account for the loss of return while shifting, but I have no idea about the neutral issue.  Should I look there?

SuzukiSavage.com » Powered by YaBB 2.2! YaBB © 2000-2007. All Rights Reserved.