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Message started by Coaxial on 08/24/15 at 07:26:41

Title: Clutch Replacement Parts
Post by Coaxial on 08/24/15 at 07:26:41

Hey Everyone,

I will be undertaking a clutch replacement in a few months. I am gathering items I need.

So far just:
+Friction plates
+Gasket
+Perhaps a new clutch cable just for peace of mind?

And yes I read about how it may not be needed for my bike but due to me being hard on the clutch, learning engine braking. It is slipping and losing power.

I have been always using Rotella T6 and I am now at around 50,000 km and most of it done in a very congested city area. I have tried to adjust the clutch and it did not help. I considered clutch rod, but that seems a bit complex for me, so I will just take on replacing the clutch.

Title: Re: Clutch Replacement Parts
Post by Dave on 08/24/15 at 07:42:30

604C425B4A424F230 wrote:

I considered clutch rod, but that seems a bit complex for me, so I will just take on replacing the clutch.

Replacing the clutch rod is less than half as complicated as the replacement of the friction discs.

Is the end of the lever at the engine between the two marks on the case.....when you lightly push up on the lever?

Title: Re: Clutch Replacement Parts
Post by Coaxial on 08/24/15 at 07:53:48

I cannot push up the lever freely.

Here is a pic
http://i.imgur.com/diWzdrMl.jpg

Title: Re: Clutch Replacement Parts
Post by verslagen1 on 08/24/15 at 08:02:47

looks like it needs a new rod to me.

There are two marks on the case behind the lever and you look to be over the top one.

There are 3 replacement rods, fairly cheap, get 1 of each.
I custom grind mine so I get 12.5mm of rod protruding from the clutch pack.

Title: Re: Clutch Replacement Parts
Post by Coaxial on 08/24/15 at 08:12:17

Where would I obtain these rods? I am in Canada fyi.

Title: Re: Clutch Replacement Parts
Post by verslagen1 on 08/24/15 at 09:05:50

0E222C35242C214D0 wrote:

Where would I obtain these rods? I am in Canada fyi.

same place you got your other parts.
As an alternate, full hard Ø1/4" dowel pins

Title: Re: Clutch Replacement Parts
Post by Dave on 08/24/15 at 09:39:05

The parts are available from the dealer.....part number 22 in the diagram linked below:

http://www.hondaofflorence.com/fiche_section_detail.asp?section=82431&category=Motorcycles&make=SUZUKI&year=1996&fveh=1886

Title: Re: Clutch Replacement Parts
Post by Coaxial on 08/24/15 at 14:11:13

Thanks guys, I bought all 3 rods from a local parts store. Will come soon.

Which clutch rod is ideal to use?

Title: Re: Clutch Replacement Parts
Post by verslagen1 on 08/24/15 at 14:30:27

The longest one that will fit under the cover w/out activating the clutch.
As I said, I shoot for 12.5mm sticking out. 13 is too much, 12 too little.