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General Category >> Rubber Side Down! >> LS650 Clutch Release Cam Breaking
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Message started by bills6h2u on 07/10/25 at 02:50:23

Title: LS650 Clutch Release Cam Breaking
Post by bills6h2u on 07/10/25 at 02:50:23

Hi

I am new to the forum and have a question regarding clutch release cam breaking. I have broke two in 600 miles. I installed new clutch plates with original springs, adjustested cable for free play.
What is the cause? Have I not assembled the clutch correctly?
Any help would be appreciated. Thanks

Title: Re: LS650 Clutch Release Cam Breaking
Post by Dave on 07/10/25 at 03:47:27

How many miles did you have on the bike prior to breaking the cams? Did you only start breaking the cams "after" you installed new plates and springs?

The OEM clutch cam is a known weak spot and they can break - but breaking 2 in a short period of time is not normal. Most folks break them when they install stronger springs, washers or do something to make the clutch grab a bit harder.

On the side of the clutch cover are marks that indicate the proper position of the chrome release lever when the clutch is engaged (hand lever fully out). The lever on the side should be between the marks. Unfortunately with a broken cam you won't be able to know where the lever is until you put a new cam in.

When you install the new cam and put the cover on - there should be some freeplay of the lever. You should be able to move the lever a small amount before it engages the springs.

Also check the condition of the shaft that the slides onto. The flats should not have rounded edges and the cam should not have a lot of rocking movement. DragBikeMike has inserted a shim on his clutch rod to make the cam fit better.

I have attached a link to the thread that shows the shimming of the shaft.

(NOTE: There once was a batch of specially made clutch cams available that were much harder than the OEM ones that are made from pressed metal. Unfortunately Sneeze had a fire in his garage and all of the unsold ones were lost).

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1615547049/15

Title: Re: LS650 Clutch Release Cam Breaking
Post by bills6h2u on 07/10/25 at 04:16:20

The Savage is new to me, bike has 26,000 miles on it. The bike wasn't running when I got it. The clutch was slipping so I ordered new Barnett steel plates,friction plates and springs. I watched the youtube video on adding the shim to the shaft, I have put in that shim. I replaced the oring on the plunger shaft with one from Suzuki. Plunger was tight with that factory oring. Less that 200 miles when first cam broke.
Pulled clutch apart, removed Barnett springs in case they were too stiff. Replaced plunger oring to get better fit. Put in used original factory springs. Reassembled and checked the lever was within the case mark indicators.
Clutch springs still too stiff?

Title: Re: LS650 Clutch Release Cam Breaking
Post by DragBikeMike on 07/11/25 at 00:27:55

You might find these videos helpful. They are in no particular order, but the should cover everything you need to know about clutch setup on an LS650.

How to check clutch free play

https://www.youtube.com/watch?v=fzrkDOeU5hs

LS650 Clutch removal & primary inspection

https://www.youtube.com/watch?v=reNteqyw72Y

LS650 Clutch Release Cam Lost Motion Check

https://www.youtube.com/watch?v=zmzxlKaLVJA

LS650 Clutch Pack Disassembly

https://www.youtube.com/watch?v=M9WnfCZlP2k

LS650 Clutch Pack Reassembly

https://www.youtube.com/watch?v=vJE6G0MjYbI

LS650 Clutch Assembly Reinstallation

https://www.youtube.com/watch?v=RoS1Lr1cTTs

Selecting Correct Clutch Pushrod and Adjusting

https://www.youtube.com/watch?v=2iSvcwOYaAs

Checking Spring Preload – Installed Height

https://www.youtube.com/watch?v=b15OGCy4kac

Shimming the clutch release cam

https://www.youtube.com/watch?v=ccZbhM9J5PA

Title: Re: LS650 Clutch Release Cam Breaking
Post by bills6h2u on 07/11/25 at 02:09:47

Thank for your help, Iwill check them out.