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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Lost my clutch lever today /cgi-bin/YaBB.pl?num=1716665412 Message started by transam4life on 05/25/24 at 12:30:12 |
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Title: Lost my clutch lever today Post by transam4life on 05/25/24 at 12:30:12 I was riding on a busy street and was coming to a stop so I started to downshift. I noticed when I hit first gear I stalled and the back wheel locked up a bit. I thought it was odd, until I noticed the my clutch lever was completely slack. At first I thought the clutch cable snapped, but I checked and its def connected on both sides. I can manually move the gear lever on the side of the engine case, but it seems like its connected to nothing inside. The engine sounded a bit rough so I turned the bike off right away. From what I'm reading it might have been the clutch cam that broke loose inside. Hopefully it didn't damage any of the engine. Any other ideas of what it would be? Is the clutch cam easy to replace? |
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Title: Re: Lost my clutch lever today Post by Michael Moore on 05/25/24 at 13:40:19 I pulled a clutch cam from a spare cover yesterday, and it is easy to do, just remove a cotter pin. BUT, the cam wears on the shaft and I had to lightly smooth a bit of erupted metal on the shaft with a diamond file before it could be removed from the cover http://eze-lap.com/woodworking_shop_machine_use/special-use-files/ So check the shaft carefully and don't force it out and bugger up the bore in the cover. |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/25/24 at 15:19:31 https://ibb.co/SPcK7xX https://ibb.co/brshRRZ https://ibb.co/rFFtc9c I just opened up the side cover and sure enough the clutch cam exploded in two pieces, luckily no other damage that I can tell. What would case that on a stock bike with 25k miles? How does the shaft look? https://suzukisavage.com/yabb2.2/Attachments/clutch_cam.JPG As far installation on the diagram above...Do I just buy a new pin #28 and slide the shaft out and then install the new cam #23? |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/25/24 at 15:21:57 https://ibb.co/7vNWNNf That is the cam chain tensioner. My digital caliper was broken, but it looked like 22mm. Should I replace that with a modified one? I bought one years ago and never got around to installing it. |
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Title: Re: Lost my clutch lever today Post by verslagen1 on 05/25/24 at 15:27:08 383E2D223F2D217820252A294C0 wrote:
can't see your pic but if it's anywhere near 22, then it's time to replace. |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/25/24 at 15:29:34 372433322D2026242F70410 wrote:
can't see your pic but if it's anywhere near 22, then it's time to replace.[/quote] I fixed the photo |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/25/24 at 15:34:51 I did have 3 questions on the cam chain tensioner... 1. How do I remove the small snap ring holding the top side of the factory cam chain tensioner if I don't have special pliers without damaging it? 2. The new cam chain tensioner has 2 holes, do I use the inner or outer one? 3. The new cam chain tensioner has a plastic yellow piece holding it together. Do I just pull that out once its all bolted in? Do I just pull it out with needle nose pliers? |
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Title: Re: Lost my clutch lever today Post by Graybeard on 05/25/24 at 19:29:38 Replace that ten cent ORing in the side cover that the shaft goes through. Ask me how I know. A stupid little drip that is such a hassle to fix..Verrry irritating. Owell, I carried a couple of the two stroke oil tiny little oil jugs. If it's oil change time and churning through the oil, it's enough to get a guy to somewhere to get enough to get home. |
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Title: Re: Lost my clutch lever today Post by verslagen1 on 05/25/24 at 20:12:24 3C3A29263B29257C24212E2D480 wrote:
I have used a small screwdriver, but you have to be careful. Quote:
Use the one that fits best, don't force it into the 2nd hole just cause you're lazy, but if it's near 22mm it probably go into the 2nd hole. Quote:
yes, it's not tight, fingers will do. |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/25/24 at 22:42:45 6C594A52494E4A594F2B0 wrote:
Thanks for the heads up. While at the dealership today ordering the new clutch cam I got a new o-ring and spring for the cam. How easy is it to install the new clutch cam? It seems pretty straight forward...remove cotter pin, slide shaft out, install new o-ring and install cam on to spring. Do I have it right? |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/25/24 at 22:44:52 3E2D3A3B24292F2D2679480 wrote:
I have used a small screwdriver, but you have to be careful. Quote:
Use the one that fits best, don't force it into the 2nd hole just cause you're lazy, but if it's near 22mm it probably go into the 2nd hole. Quote:
yes, it's not tight, fingers will do.[/quote] Awesome, thanks! When you say don't force it into the 2nd hole, do you mean in the inner one by the tensioner or the outer one futher away? Also, any idea what the torque spec if the cam chain tensioner bolt? |
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Title: Re: Lost my clutch lever today Post by DragBikeMike on 05/25/24 at 22:51:45 Transam, do a good visual inspection for cracks in your clutch cover. I can see from your picture indications that look an awful lot like cracks. The remnants of the cam may have gotten wedged between the rotating clutch and the cover. This markup shows what I am concerned about. |
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Title: Re: Lost my clutch lever today Post by DragBikeMike on 05/25/24 at 23:03:53 "As far installation on the diagram above...Do I just buy a new pin #28 and slide the shaft out and then install the new cam #23?" That's pretty much all there is to changing the cam, but pay attention to Micheal Moore's comment about deburring the shaft before you try to pull it out of the clutch cover. Burrs develop on the shaft as it gets worn by the cam. The burrs tear up the bore in the cover when you remove the shaft. If you go to pull out the shaft, and if it's tight or feels like it's binding, STOP. Push it back in and clean up the burrs. This YouTube vid will give you more than enough detail on replacing the cam. https://www.youtube.com/watch?v=ccZbhM9J5PA |
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Title: Re: Lost my clutch lever today Post by Dave on 05/26/24 at 02:51:18 Why did the clutch cam break? Because they are not all that strong and it is not uncommon for them to break. Unfortunately you ordered a new one from Suzuki. Our forum member Sneeze had some much stronger ones made by a machine shop that don't break. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1694897686 |
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Title: Re: Lost my clutch lever today Post by Graybeard on 05/26/24 at 04:51:05 They are sintered metal. Powder, compressed. And the geniuses failed to radius the inside ninety that is stressed in every lever pull. Clutch less shifting is so easy on these things. Everything except for first to second,, too big of a jump for me to master it quickly enough to not be concerned about hurting it. It's easier if you're running pretty hard,something above easy cruise mode. To get it down, I put my palm on the gas,toe under the shifter, and just as the torque starts to fade, shove the hand forward and jack the toe,the hand should be back ,gas on, just a quick OffOn, with a shift in the middle. Play around in the upper gears,fourth and fifth, you can do those without much effort. I don't Have to be hustling to shift it, but it's easier. It's how I started. If you don't get back on the gas, no harm, it just slows down, so if ya just want to slap the throttle shut and shift up as soon as the transmission is unloaded, in the place between acceleration and deceleration, just to prove to yourself that you can change gears and not need floor dry and a broom,, that sounds okay, too. The previous comment is for information and entertainment only. Don't try this at home. Or if you Want to Get home.. |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/26/24 at 07:47:38 64626D11131410200 wrote:
Thank you for showing me that picture. I actually noticed that last night and wondered if that was a crack as well. I plan on taking a 2nd look later today. If that is indeed a small crack the only repair is by buying a new clutch cover correct? |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/26/24 at 07:52:53 0B0D027E7C7B7F4F0 wrote:
Awesome, that explains everything! I will def be deburring as well if needed. Am I suppose to buy a new shaft as well when replacing the cam? The video shows quite a bit of play from a used shaft and new cam. He talks about a shim, but not sure where I would get one of those from... |
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Title: Re: Lost my clutch lever today Post by Graybeard on 05/26/24 at 08:06:07 Get a cam. See how it fits the shaft. |
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Title: Re: Lost my clutch lever today Post by Michael Moore on 05/26/24 at 09:02:40 2F293A35283A366F37323D3E5B0 wrote:
DBM made the shim from a feeler gauge of an appropriate thickness. |
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Title: Re: Lost my clutch lever today Post by ThumperPaul on 05/26/24 at 10:06:34 And the guru in the video is DragBikeMike himself! Sadly, The Sneeze lost his shop in a fire and his custom-made hardened clutch cam production isn’t a priority for him right now. |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/26/24 at 11:08:10 5A6F7C647F787C6F791D0 wrote:
Yeah I already have the cam on order, the shaft was $90 so I held off on that assuming I could reuse, but if I have to buy a new one I will. How much play should there be on the cam? |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/26/24 at 11:08:49 486C666D646069486A6A7760050 wrote:
DBM made the shim from a feeler gauge of an appropriate thickness.[/quote] How much play is normal? |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/26/24 at 11:11:53 https://ibb.co/3pzDQJx https://ibb.co/dKLmGhH https://ibb.co/XJTQ9Pw https://ibb.co/ZxRpRd2 https://ibb.co/7bMSfBh I took some additional photos of the inside of the case. To the best of my knowledge it doesn't seem cracked...just casting marks. I found other spots inside the case that look similar. What do you guys think? |
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Title: Re: Lost my clutch lever today Post by Michael Moore on 05/26/24 at 13:41:28 You might want to get a dye penetrant crack testing kit or supplies to be sure: https://grassrootsmotorsports.com/articles/testing-cracks-home-diy-dye-penetrants/ but the materials aren't inexpensive https://www.amazon.com/Dye-Penetrant-Crack-Finder-Kit/dp/B00XLW4BRC/ref=sr_1_3 |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/26/24 at 13:55:45 51757F747D79705173736E791C0 wrote:
That's pretty neat...I didn't know they made such a kit. I think a new clutch cover is $225 brand new or much less used on Ebay so I'm not sure investing $75 would be worth it for the kit. Maybe I can take it to a machine/race shop and see if they can check the crack for me for a smaller fee. |
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Title: Re: Lost my clutch lever today Post by Michael Moore on 05/26/24 at 16:48:57 A place that maintains airplanes or big diesels is another possibility for having crack detection stuff on hand. "magnaflux" only works on ferrous materials so non-ferrous like aluminum gets dye penetrant tested or x-rayed. |
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Title: Re: Lost my clutch lever today Post by DragBikeMike on 05/26/24 at 18:37:18 "Thank you for showing me that picture. I actually noticed that last night and wondered if that was a crack as well. I plan on taking a 2nd look later today. If that is indeed a small crack the only repair is by buying a new clutch cover correct?" I got to thinkin about this supposed crack and how it could be just casting flash, so I disassembled my spare cover and took a look see. Whadyaknow, same thing. |
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Title: Re: Lost my clutch lever today Post by DragBikeMike on 05/26/24 at 18:40:06 Examination at 5X indicated casting flash. To make sure, I polished it with 220 grit wet & dry abrasive. All gone in just s few minutes. I think your cover is just fine. Polish the blemish with 220 grit and verify that it disappears. Then forge ahead. Sorry for any confusion. Always better safe than sorry. |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/26/24 at 18:44:51 Thanks to DragBikeMike and Michael Moore for the help with the clutch cover "crack". After seeing your photos I think it is casting flash as well. Would sanding down the part effect the cam positioning at all? I know it sits on that "slopped ledge"... |
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Title: Re: Lost my clutch lever today Post by DragBikeMike on 05/26/24 at 19:59:04 Sanding that hard-stop won't hurt anything. You only want to remove the visual indication. If it turns out to be an actual crack, you will wear your finger out before you hurt the hard-stop. |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/26/24 at 20:29:53 Ok I will sand it. So just 220 wet/dry sandpaper...am I suppose to wet sand it or does it not matter? Can I use that same sandpaper to clean up any metal burrs on the shaft or would that be too rough and a diamond file like was recommended earlier be better? Speaking of the shaft, would you recommend I change the shaft out as well if replacing the cam. I have a feeling there will be too much play with the worn out shaft. I guess time will tell once the part arrives. |
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Title: Re: Lost my clutch lever today Post by verslagen1 on 05/26/24 at 20:59:14 can't be 100% sure but I've seen those before and they're just casting marks. dye pen accumulates in any crevice and those casting marks will be a lot of false positives. to get a true reading, you'll have to polish out all the marks then etch the surface because polishing will fill any cracks and etching will remove the fill. |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/26/24 at 21:49:19 What would I etch the surface with? |
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Title: Re: Lost my clutch lever today Post by ThumperPaul on 05/27/24 at 05:33:35 Dumb question from the peanut gallery…. Why bother doing anything (sanding, etching, etc.) about the casting imperfections? Haven’t they been there forever? Seems like sanding it is purely cosmetic to me. If oil ain’t coming out the other side, slap it back together. Then if it develops a leak down the road, put a new case cover on it. Those superficial marks don’t look like they’d develop into a full blown gusher. Please don’t listen to me know. Listen to the gurus. |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/27/24 at 07:27:43 I believe why they are concerned about the possible crack is not so much about an oil leak. It's about stress on the metal where the clutch cam rests against and eventually the pressure would blow out the side case and cause another failure. I will say losing your clutch out of nowhere is a scary feeling and luckily I didn't crash. I was coming to a stop while downshifting when I realized it went out. I just kept downshiting all the way to first without the clutch until it finally stalled because trying to find neutral without a clutch is impossible.The back tire even locked up a bit and slid, but I was able to control it. This all happened on a very busy road, but luckily I was able to push the bike on to some grass and get out of the way. Is there anything other tips I should know in case this or another clutch issue ever happens again? What would have happened if my clutch went out on the highway? Same thing...just downshift and slow down as best as possible without the clutch? |
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Title: Re: Lost my clutch lever today Post by Michael Moore on 05/27/24 at 08:28:14 The use of the diamond EZ-Lap was because it fell readily to hand, I didn't know if the shaft was going to be too hard to use a file to take off the burr, and the EZ-Lap isn't very aggressive and I didn't want to take off any more metal than necessary. It likes any good small/smooth file will do the job. Yes, my concern would be a case failure, and if you ever do spot oil starting to come through the case I'd expect that failure would be arriving shortly. But if you can avoid using the clutch in that situation you'll avoid stressing the case and might be able to get home safely. |
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Title: Re: Lost my clutch lever today Post by ThumperPaul on 05/27/24 at 09:35:21 That’s definitely scary, TransAm! Since y’all are reasonably convinced it’s not actually cracked and the cam self-destructed without blowing a hole thru the case, I think you’ll be alright. Apparently the raised stop in the case side is pretty tough to endure an exploding clutch cam! |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/27/24 at 10:20:29 Would you guys recommend I buy a new clutch shaft arm? My bike has 25,000 miles, so now I thinking that putting a brand new cam on a used and worm shaft arm will cause significant play and wiggle. I looked up the shaft arm and I can get it for $86. I don't want to spend the money if I don't have to, but if it provides peace of mind that a new one won't tear up the cam I don't mind paying for it. |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/27/24 at 10:38:33 Also, my motorcycle is a 2008 model year. What about replacing the clutch cable itself while I'm doing all this. What is the interval recommendation for that? |
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Title: Re: Lost my clutch lever today Post by ThumperPaul on 05/27/24 at 10:43:14 I’d do the shaft/release arm while you’re already in there. Unless the cable is damaged, it’s probably okay. Cable lube it. |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/27/24 at 11:05:59 What is the best way to lube the clutch cable? It looks like that make some sort of clamp on tool... https://www.amazon.com/Motion-Pro-08-0182-Cable-Luber/dp/B0012TYX9W/ref=sr_1_5?crid=1YCQD0OR0SLWH&dib=eyJ2IjoiMSJ9.FiecGFEd3Qc5WZf3CXpicLrYNlBNktzWArKup-T9frhZKTovtMN7x7uacZP1jXVTISBCdT3RrO_LsMWX_0kaUwsHkbmU-9aM3-rVE4iOivzWy8KG7THFAG3lyCAl8DONOIKUlO8rgOOC3Ll8fxqYNfgWPySmZeRG5VxZKKbzHegPGmeZCtqPjgj_odpGt4Waxhh0RzWHKM2AZpWStB91vL6Njw3K01E39-oPiqSgj7NDTRdgJnTw9RK6TziJ56BBJtAyr7ujflBW0lyjMv9HNSZ0o8C6vuOkY4ACDYqfq1Q.tR6RACvfO8A3F5RRlHAtq0UboFx_z_5TuSfYq4XdH9c&dib_tag=se&keywords=cable+lube&qid=1716833123&s=automotive&sprefix=cable+lube%2Cautomotive%2C147&sr=1-5 |
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Title: Re: Lost my clutch lever today Post by verslagen1 on 05/27/24 at 11:33:30 6365767964767A237B7E7172170 wrote:
and a can of spray lube OR cut the corner off a small baggie just enough to slip over the end of the cable, seal the baggie to the cable by wrapping a rubber band around it, hold the baggie up a bit and pour some oil into it and then let gravity do its work. |
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Title: Re: Lost my clutch lever today Post by verslagen1 on 05/27/24 at 11:42:31 4F736E766B7E694B7A6E771B0 wrote:
I don't recall anyone saying they've developed a leak in a clutch or stator cover. Oil filter cover because someone installed the oil filter in backwards. Case cause the vibration damper wanted to see new sights. |
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Title: Re: Lost my clutch lever today Post by Michael Moore on 05/27/24 at 12:59:28 It appears to me that the cam and shaft are kind of "pre-broken" from Suzuki due to the excess slop. The wear you see on those corners seems to be the way they all end up sooner or later. I think that right now instead of a new shaft you should buy some feeler gauge stock in different thicknesses and try to shim between the cam and shaft as DBM does. It would be less expensive, and even if you get a new shaft and stock cam they should also be shimmed from the start. Of course, you still have a potential sintered cam failure in your future. Inspect your clutch cable where the cable goes into the soldered fittings at the ends. The typical failure mode is for an end to get seized in the lever so it doesn't swivel freely, causing the cable to flex back and forth where it comes out of the fitting. Eventually you get a fatigue failure there. The lever at the case has a swivel fitting built in and should be fine but if the pivot pin is gunked up and binding you could have problems there. But the hand lever is the usual spot as no one ever looks at the cable end hiding on the underside of the lever. If you don't see any kinks or frayed wires, then give the cable a good lube (and relube it now and then). If it seems to move smoothly inside the housing then I'd say it is probably fine to put back into use. If you aren't doing a lot of stop and go traffic, then 99% of the time the cable is just sitting there without any tension/flex happening to it and it has no reason to wear. |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/27/24 at 18:40:50 I installed the modified cam chain tensioner. How does it look…was the 2nd hole appropriate? https://ibb.co/BZHYL5s I mangled the c-clip trying to get it off with a screwdriver. I finally caved and went to buy the proper pliers and it was cake. Maybe I’ll replace the c-clip just to be sure. |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/27/24 at 18:44:34 Also, I should have been better attention. But does the brake pedal return spring go behind the black frame part like I have it in the photo or in front? https://ibb.co/pWW4tgz |
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Title: Re: Lost my clutch lever today Post by verslagen1 on 05/27/24 at 18:51:17 yes, it goes behind or it's too loose yes tensioner looks fine |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/27/24 at 19:17:35 Thanks verslagen for confirming. I bought the cam chain modification from you years ago and kept putting it off, until I no longer had a choice with the clutch going out...haha! Def was easier than I expected. Now I just have to wait for the clutch parts to arrive. I do have one question regarding the exhaust. I was not able to remove the entire exhaust as one piece. I just removed the header pipe. The muffler was replaced with a Jardine and for the life of me I couldn't figure out how to get a socket on the 2 bolts as the rubber piece was in the way. What did I do wrong? https://ibb.co/KNqRMHp https://ibb.co/XskkxgY https://ibb.co/FHmyhvp Also, should I use antiseeze on the header pipe bolts when I reinstall? I already have the new exhaust gasket... |
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Title: Re: Lost my clutch lever today Post by Graybeard on 05/28/24 at 18:10:33 What is that thing that is like a collar around the head of the bolt made of? I'm guessing that is what is holding up. Anyway, sockets and box end wrenches are chamfered to make getting them on a bolt easier. I've had to grind them flat to get them to engage low bolt heads. A thin walled socket is your friend here. You may have to get it on and smack it .A few quick raps is better than trying to smash it. If that doesn't work, sacrifice the socket and grind it thinner? |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/28/24 at 21:57:34 Its some sort of rubber washer gasket/washer. I'm not sure if its a stock part or because I have an aftermarket exhaust. There is no way I could get a socket on the bolt head. |
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Title: Re: Lost my clutch lever today Post by Dave on 05/29/24 at 03:34:21 It looks like somebody didn't put a flat washer under the bolt head, and the bolt head has recessed into the rubber bushing. |
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Title: Re: Lost my clutch lever today Post by ThumperPaul on 05/29/24 at 06:02:46 That’s almost exactly the way my Verslavy CCT looked when I installed it on the 2nd hole. My thinking was - if the plunger let me get it in the 2nd hole, it must be okay. If you had used the 1st hole, you’d probably have to move it to the 2nd hole within 1000 miles the way it appears. 2nd hole gets my vote for the right hole in your condition. I’d buy a new c-clip for such an important little fastener. It would be hard to see if you “wollered-out” or bent the old c-clip with the screwdriver (that would be something that would happen to me.). I also broke down and bought the special pliers (good little tool investment). Also, a dab of some red threadlocker for the bolt holding the CCT. I like Verslagen’s tip on how to make a “catch funnel” out of a plastic bag to lube the clutch cable. I’ve been known to just use a rag and make a mess as I squeeze some oil in there and let gravity do the work. For the muffler mount bolts, I agree with Dave and Graybeard. And squirt some PB Blaster in there as best you can and try a box end wrench. Give the PB Blaster 15-20 minutes to work and it may need multiple doses to get the funk out. I use anti-seize on the header bolts and torque to 19nm. Max torque for the header bolts is 28nm “dry bolts” (Clymer Manual). Rule of thumb is use 30% lower torque when anti-seize is used, so I go 19nm. And that feels about right. Any more would feel scary. I may have hit 19.5nm. |
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Title: Re: Lost my clutch lever today Post by Michael Moore on 05/29/24 at 09:04:04 3630232C31232F762E2B2427420 wrote:
Now might be a good time to install some studs at the exhaust manifold and nip a potential future problem in the bud. |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/29/24 at 09:11:48 Thanks for all the tips ThumperPaul! Yeah new c-clip is on the way…I didn’t want to take any chances. Regarding the cam chain tensioner bolt, you are the first I’ve read to put thread locker on the bolt. Any reason why I should use red vs blue thread locker if I use it? Also, what is the torque spec for that bolt?…I believe the manual lists 2 different numbers. I just snugged it by hand. I splurged and bought a motion pro cable luber, so we’ll see how that works…but thanks for the bag trick tip! As far as the muffled bolts…it’s not a matter of rust. I live in the southwest so rust really isn’t an issue. I bought the bike used with the muffler already installed and I’m starting to think they missed a washer or something on the installation. I literally can’t get a socket to grab the bolt because the rubber washer is blocking it. Does anyone have a photo of the stock muffler bolts to get an idea of what it should look like? I guess it’s not a huge deal in the I was able to just get the header pipe out by itself. Speaking of which…Does any regular anti-seize work for the header bolts or should I look for something special? |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/29/24 at 09:13:09 71555F545D59507153534E593C0 wrote:
Now might be a good time to install some studs at the exhaust manifold and nip a potential future problem in the bud.[/quote] Sorry I’m not familiar with studs…how would that work? |
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Title: Re: Lost my clutch lever today Post by ThumperPaul on 05/29/24 at 10:33:47 I think Micheal was referring to the header “bolts”. Our bikes have pretty chrome cap “bolts”. Many motorcycles have threaded “studs” that install into the exhaust manifold/head and then use nuts to mount the exhaust header flange. Our bikes really don’t have an exhaust “manifold” per se either. I think this is just a terminology miscommunication. Or maybe Michael is suggesting swapping out the header bolts and replacing them with studs and nuts. And I think Dave is right. Someone left out the flat metal washers on the muffler bolts and just cranked ‘em down until the rubber grommets got crushed to sh!t. Try to get an open end wrench on ‘em. Or whip out the vise grips and give that a try. If all else fails, chop ‘em off with a cutoff tool and install fresh hardware. |
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Title: Re: Lost my clutch lever today Post by DragBikeMike on 05/29/24 at 12:08:39 "Sorry I’m not familiar with studs…how would that work?" This will give you the info you need regarding the exhaust studs. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1665791582 |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/29/24 at 12:59:37 Thanks for the link on exhaust studs! |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/29/24 at 13:01:23 http://suzukisavage.com/cgi-bin/YaBB.pl?num=1467342392/13 I found that thread about using Loctite on the cam chain tensioner bolt…about 50/50 mixed opinions. Also, what is recommended torque spec for the bolt…I still can’t find it. |
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Title: Re: Lost my clutch lever today Post by ThumperPaul on 05/29/24 at 14:17:51 Clymer Manual Says. Cam Chain Tensioner Set Bolt 20-25nm (14.5-18.0 ft.-lb.) Plate Bolt 8-12nm (6-8.5 ft.-lb.) |
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Title: Re: Lost my clutch lever today Post by transam4life on 05/29/24 at 14:39:43 I saw those specs too. That’s what confusing me…is it the set or plate bolt? The CCT only has one bolt…the other side is held in place by a c-clip. |
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Title: Re: Lost my clutch lever today Post by ThumperPaul on 05/29/24 at 15:12:29 The set bolt is what the c-clip is attached to. It's actually a threaded bolt. The torque spec on it seems high to me, but that's what it says. The plate bolt is what attaches the CCT to the rear cam chain guide. Ain't no way you've ever put 20nm of torque on that puppy without snapping the guide. That said, be sure to hold that nut on the backside of the guide with a wrench when you tighten it so you don't twist and break the guide. |
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Title: Re: Lost my clutch lever today Post by transam4life on 06/01/24 at 18:59:00 Thank you guys for all the help! Clutch cam assembly and modified cam chain tensioner installed…everything looking good so far. https://ibb.co/9VMvcTz https://ibb.co/mtvg6jt |
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Title: Re: Lost my clutch lever today Post by ThumperPaul on 06/01/24 at 19:40:19 Both look good. Nice job! Did you use loctite or skip it? Good job of that circlip! I had nightmares about that thing flying across the garage and disappearing into never-never land! |
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Title: Re: Lost my clutch lever today Post by transam4life on 06/01/24 at 20:10:10 Yeah I went through 2 c-clips trying to remove/install it with a screwdriver. I finally wised up and bought a pair of snap ring pliers…it’s amazing how easy it was after that. I did use Loctite on CCT bolt. I happened to have a tube of blue Loctite already opened so I used that. It’s says it’s good for up to 300F degrees. All looks/sounds good so far! I’m also happy that I bought a new clutch arm to go with the new cam…there was significant wear on the old arm. |
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