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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Clutch cam probably broken /cgi-bin/YaBB.pl?num=1533781090 Message started by Tocsik on 08/08/18 at 19:18:10 |
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Title: Clutch cam probably broken Post by Tocsik on 08/08/18 at 19:18:10 Lost my clutch on the ride home from work. Thinking it was a busted cable, I nursed it home. When I got home I did some reading here, some more looking at the bike and discovered it's most likely the clutch cam and probably shouldn't have been running the motor. Hope all is going to be OK in there :(. Anyway, I think I need parts #23 and #28 in the diagram for the '08 (cam and pin). https://www.bikebandit.com/oem-parts/2008-suzuki-boulevard-s40-ls650/o/m147543#sch552680 Wondering if it's OK to go ahead and order them before cracking open the clutch cover so I can get them on their way. Or, are there any reports of the spring also breaking? Guess the best course is to wait until I open her up. Also, with about 18,500 miles, should I go ahead and order the longer push rod? VerSlavy CCT done at 10K miles. And less than 1,000 miles on this oil, too >:(. |
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Title: Re: Clutch cam probably broken Post by verslagen1 on 08/08/18 at 20:37:30 I would crack it open right now, you're not going to ride till it fixed. Figure out what you need and order it. It would be a pisser find out it's something else or you need something and have to wait again. If you're really careful, you can take the cover off and not tear the gasket. order all 3 pins, they're cheap. when you put it in, measure, should not stick out more than 12.5 mm. and when you put the cover on check clutch operation. |
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Title: Re: Clutch cam probably broken Post by batman on 08/08/18 at 20:39:29 Why guess? I'd look first, you may need the side cover gasket, exhaust header gasket as well as other parts ,and why order parts that you may not need to replacement. Sure you may save time, but you might save money on free shipping if the parts are ordered all at once. You haven't described what happened or why you think it's those parts that need replacement. Vercy ,I think he's talking about pin #28(cotter pin?) while your talking about pin #22 of which there are three different lengths. I'm confused by the fact that I don't know if his clutch is not engaging or not disengaging. |
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Title: Re: Clutch cam probably broken Post by verslagen1 on 08/08/18 at 22:24:34 5D666A7A6062090 wrote:
:-? |
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Title: Re: Clutch cam probably broken Post by eau de sauvage on 08/09/18 at 02:27:53 should I go ahead and order the longer push rod? I've always wondered about this, does it come with the middle one as standard or the shortest one as standard? According the range mark on the clutch cover, it's already close to the end of it's range when new! |
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Title: Re: Clutch cam probably broken Post by Tocsik on 08/09/18 at 06:16:24 The lever is slack and the arm is dropped, clutch won't disengage. Pulled away from a light and something gave when I pulled the clutch to shift to 2nd and the lever became slack. I pulled off to check the cable and the end at the lever felt like it was moving independent from the end at the arm on the case, as if the cable was broken somewhere in the middle inside the sheath, which seemed odd. Never heard of the clutch cam until I got home and did a search here. Checked the bike again out in the garage and found the arm was not staying in position and my initial check of the cable was flawed because the sheath was moving at the lever when I checked the end at the arm. Cable is intact. Spring inside the case actually feels OK. Will pull it apart tonight if possible or this weekend. Thanks all. Versy, your second response specific to the push rod just has an emoji. Can you expand on that? Maybe the shorter push rod is needed with wear? I haven't had time to read up on that yet. I never pretend to be more knowledgeable than I am and always eager to learn. Thanks. |
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Title: Re: Clutch cam probably broken Post by Dave on 08/09/18 at 06:28:55 The pin marked #28 is just a cotter pin....it is nothing very special. The #23 cam has a round hole with flat sides.....and that is where the force is applied from the shaft to the cam. Some members have reported the cam breaking when they installed washers under the springs to make greater force on the clutch to help prevent slippage......I am not sure anyone has broken this piece with the stock springs (yet).....or with the claimed 10% stronger aftermarket spring kits. Do you have the stock springs in the clutch? It is reported that this piece is made from sintered metal that is molded into the needed shape......perhaps we need somebody to make a stronger version using real steel! The only difficult part I see is in making the shaft hole with the flat sides and rounded ends......I guess that requires a proper sized "broach" to make the hole. |
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Title: Re: Clutch cam probably broken Post by verslagen1 on 08/09/18 at 07:13:40 7C6F7879666B6D6F643B0A0 wrote:
:-?[/quote] Quote:
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Title: Re: Clutch cam probably broken Post by batman on 08/09/18 at 10:09:15 I'd be checking to see if the clutch cable snapped ,before doing anything else. have you ever lubed the cable? If the lever is slack and the arm at the case has dropped the only thing that connects them IS the cable. disconnect the cable at the clutch lever on the bar, and see if you can pull it out , and/or check both ends of the cable to see if the fittings are in place |
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Title: Re: Clutch cam probably broken Post by Tocsik on 08/09/18 at 10:51:48 Yeah, both ends are intact and when I hold the arm down and operate the lever, the cable pulls it. Seems like the problem is inside the case. I last lubed the cables at 9300 miles but it's been operating smoothly. When I hold the arm it also seems like it's between the marks. Oh, and the clutch springs are stock. |
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Title: Re: Clutch cam probably broken Post by justin_o_guy2 on 08/09/18 at 13:30:33 Recommend new oring for the shaft. |
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Title: Re: Clutch cam probably broken Post by Tocsik on 08/09/18 at 19:27:00 Sucker broke clean in half. Both parts sitting nicely in the bottom of the case. |
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Title: Re: Clutch cam probably broken Post by Tocsik on 08/09/18 at 19:27:51 Looks like there aren't any shards missing. |
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Title: Re: Clutch cam probably broken Post by OCMike_LS650 on 08/15/18 at 12:20:28 I bought a 01’ with this problem. I replaced the same broken piece. I’ve taken it apart almost six times now and stilll can’t figure out the problem. New clutch cable ,still won’t work properly. When I put everything back the lever sits under the two marks. It does not sit straight at a right angle I have to note that my bracket where the cable goes through that is part of the crank case is broken. I will add a picture. The bike does run though I ran it down the alley and back with no clutch Plz help I’m about to kms |
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Title: Re: Clutch cam probably broken Post by verslagen1 on 08/15/18 at 12:39:15 555956492C2F2A1A0 wrote:
When you pull up on it with light pressure, where does the lever sit? Did you install the push rod? |
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Title: Re: Clutch cam probably broken Post by OCMike_LS650 on 08/15/18 at 13:12:23 It has play up til a little bit above the two marks I used the same push rod that was in there. |
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Title: Re: Clutch cam probably broken Post by verslagen1 on 08/15/18 at 14:17:53 020E011E7B787D4D0 wrote:
I think that is too high. the push rods are cheap, buy all three. put the one in that's over 12mm and under 13mm I usually go for 12.5 sticking out of the clutch pack. |
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Title: Re: Clutch cam probably broken Post by batman on 08/15/18 at 18:43:31 And you should repair the boss that the cable runs through , these are usually broken because a nut is wrongly placed on either side of the boss and breaks it . both the nuts should be on TOP ,the lower one to adjust the cable tension, and the upper one to lock the adjustment in place. some have simply used a small piece of flat bar steel with a hole( slightly larger than the threaded cable end) and a second hole between the clutch and speedo cables drilled into the boss and threaded for a small bolt. This works because all pressure is downward on the flat bar when you pull in the clutch lever ,there is no pressure on the plate when the lever is released. |
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Title: Re: Clutch cam probably broken Post by OCMike_LS650 on 08/25/18 at 13:30:54 Received new push rods Installed. Still no good I got a new cotter pub as well and a new spring Sits at a better position now not all the way down but still with clutch pulled in all the way , does not disengage. Stuck clutch maybe ?? |
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Title: Re: Clutch cam probably broken Post by batman on 08/25/18 at 15:36:44 OCmike did you repair the boss so it holds the lower cable shield in place? If you haven't repaired it ,you have no adjustment ,and will never have enough cable travel to pull the arm up all the way and fully disengage the clutch. |
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Title: Re: Clutch cam probably broken Post by OCMike_LS650 on 08/27/18 at 06:27:18 I zip tied it down and it pulls it a decent amount but I guess it’s not enough to disengage . I drop into first now and it will start rolling it doesn’t stall anymore , just starts rolling so that’s what makes me think the disks are stuck. Push rods didn’t do a difference. |
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Title: Re: Clutch cam probably broken Post by batman on 08/27/18 at 16:57:34 Zip ties stretch ,they won't hack it. You really need to fix this FIRST ,as I suggested this has work for others that had exactly the same problem , then test the different push rods . |
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Title: Re: Clutch cam probably broken Post by OCMike_LS650 on 08/27/18 at 19:58:42 Does anybody know which is the tallest bridge in CA ?? |
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Title: Re: Clutch cam probably broken Post by verslagen1 on 08/27/18 at 21:54:36 You need more duct tape? I think I've been under it once. https://en.wikipedia.org/wiki/Foresthill_Bridge |
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Title: Re: Clutch cam probably broken Post by justin_o_guy2 on 08/27/18 at 22:14:56 That's quite a mess.. Wonder what did that,,, |
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Title: Re: Clutch cam probably broken Post by OCMike_LS650 on 08/27/18 at 23:03:46 Clutch cam prob broke and got caught up in the clutch disks shot out a piece of the clutch cover made a mess in my neighbors driveway. Anybody in OC need parts ??? |
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Title: Re: Clutch cam probably broken Post by Tocsik on 08/28/18 at 06:18:51 Man, sorry to see this, Mike. I guess I got lucky, at least so far. Still waiting on parts to get mine back together. There may be a very small piece of the spring broken off but I won't know for sure until the new one arrives. Didn't see it inside the clutch cover and didn't pick up anything fishing around in the bottom of the case with a magnet. Anyone have a good close-up pic of the inside of the clutch cover? I'm looking for one showing the area outlined in red, taken from the perspective of the arrow. I need to see better how that spring wraps around the cam for reassembly. Thanks in advance. |
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Title: Re: Clutch cam probably broken Post by GOF on 08/28/18 at 06:24:48 58545B44212227170 wrote:
Pull the cover. Figure out what the extent of the damage is. You may be able to save her yet. |
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Title: Re: Clutch cam probably broken Post by GOF on 08/28/18 at 07:08:30 Is there a link to a how to check of the clutch rod lengths? Where the lever should be in relation to the two marks on the cover? |
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Title: Re: Clutch cam probably broken Post by OCMike_LS650 on 08/28/18 at 10:13:51 Tocsic I have opened up this darn cover about 9 times now [ch129303] The spring goes just as shown on the picture the vertical goes in between that small space on the cover and the horizontal part pointing left goes behind the cam release top part , I believe the spring is so it sets the arm lever back to where it should be between the two marks on the crank case |
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Title: Re: Clutch cam probably broken Post by OCMike_LS650 on 08/28/18 at 10:15:49 GOF there’s like a pubic hair difference between all 3 rod sizes I just received them a couple days ago. |
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Title: Re: Clutch cam probably broken Post by OCMike_LS650 on 08/28/18 at 10:20:26 Here you go tocsic |
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Title: Re: Clutch cam probably broken Post by Tocsik on 08/28/18 at 10:34:35 Thanks for that pic and description Mike. And good luck with everything. GOF - my digital caliper has a depth gauge on the end that works great for checking the push rod length. |
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