SuzukiSavage.com - Clutch problem

Jim_R

Ex Member

Clutch problem
01/01/06 at 19:08:38

So I was driving my bike and lah de dah. WHAM! No clutch. I was like uh D@MN! No tension on the lever so I made it to my friends house. We thought it might be the cable but nooooo.. that would be too easy.

After a quick call to Torque's tow truck service and garage we discovered it was a CAM,CKYTCG RELEASE.
It was broken clean in half. We removed the 4 bolts and inspected the springs and clutch. They looked fine and thank god its only a 5.00 part.

Anyone else had this happen to them?

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bentwheel Serious Thumper 2005 No Login Offline Ride free, citizen Posts: 658 Sarnia, Ontario, Canada Gender:	Re: Clutch problem Reply #1 - 01/01/06 at 20:19:23 Jim_R wrote on 12/31/69 at 16:00:01: it was a CAM,CKYTCG RELEASE. Heck, I'd have thought it was a BRIIYPTAQP.
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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: Clutch problem Reply #2 - 01/02/06 at 07:41:16 Oh. You mean the #%^&&@(@(&$! Cam Release? Why?
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Jim_R Ex Member	Re: Clutch problem Reply #3 - 01/02/06 at 07:56:44 Ok its the part number 24. I have no clue why it broke. My bike is 10 years old. Maybe stress caught up with it.
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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: Clutch problem Reply #4 - 01/02/06 at 08:03:04 I would be checking to see that #23 was freely floating in the hole and that the clutch basket releases as it should before I put it back together. Did you notice the clutch becoming more difficult to operate before it broke? Photos of the broken piece?
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torque Serious Thumper 2005 No Login Offline 2008 nightster,flat od green and black Posts: 748 rock hill,S.C. Gender:	Re: Clutch problem Reply #5 - 01/02/06 at 08:17:10 the pin is moving freely,and the clutch is fine,the cam release broke at its weekest points.
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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: Clutch problem Reply #6 - 01/02/06 at 09:16:12 torque wrote on 12/31/69 at 16:00:01: the pin is moving freely,and the clutch is fine,the cam release broke at its weekest points. #20 slides freely?
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Digger Serious Thumper 2005 No Login Offline Ya gotta be tough to ride singles! Posts: 1604 Colorado Springs, CO Gender:	Re: Clutch problem Reply #7 - 01/02/06 at 09:18:10 Take a look at the cam under a magnifying glass. When a part breaks like this, you can frequently see evidence of a crack that has been propagating slowly with time. You can sometimes see signs of corrosion on the crack surface, which means that the crack started some time ago. Interesting stuff. JIM, How many miles on the bike?
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torque Serious Thumper 2005 No Login Offline 2008 nightster,flat od green and black Posts: 748 rock hill,S.C. Gender:	Re: Clutch problem Reply #8 - 01/02/06 at 09:36:09 Savage_Greg wrote on 12/31/69 at 16:00:01: #20 slides freely? 23 slides freely,20 does not(which is a good thing) i think theres around 9,000 miles on his,if the previous owner didnt play with odometer
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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: Clutch problem Reply #9 - 01/02/06 at 10:48:11 torque wrote on 12/31/69 at 16:00:01: 23 slides freely,20 does not(which is a good thing) Oops, I meant #23 slides in #20, freely. It almost seems like #29 would have broken first.
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torque Serious Thumper 2005 No Login Offline 2008 nightster,flat od green and black Posts: 748 rock hill,S.C. Gender:	Re: Clutch problem Reply #10 - 01/02/06 at 10:58:46 #29 cant really "brake" it just a cotter pin,that holds #25 in place theres never any pressure on it. after looking at my #24 im going to get a new one, while i have it apart .theres a hell of lot of pressure on such a weak part.
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Savage_Greg

Serious Thumper
Alliance Member

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Don't go around your
ass to reach your
elbow...

Posts: 7844
SW Washington State
Gender: male

Re: Clutch problem
Reply #11 - 01/02/06 at 11:43:55

torque wrote on 12/31/69 at 16:00:01:

#29 cant really "brake" it just a cotter pin,that holds #25 in place theres never any pressure on it.

after looking at my #24 im going to get a new one, while i have it apart .theres a hell of lot of pressure on such a weak part.

Since the cam is located by the flat on the shaft, the cotter pin is probably intended to shear first. Maybe, maybe not. As Digger said, there must have been fatigue developing in the cam.

Either way, Jim gets a First Time Award for clutch breakage. I don't think we've heard of this before.

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torque Serious Thumper 2005 No Login Offline 2008 nightster,flat od green and black Posts: 748 rock hill,S.C. Gender:	Re: Clutch problem Reply #12 - 01/02/06 at 13:24:55 greg ,i think u think that the lever arm slides into the rod with the flat end and the cotter pin holds them together...this is not the case.the "L" shape #25 is one piece,with a little hole drilled in it,that the cotter pin goes into to keep the arm from sliding out of the side cover #28 is a o-ring
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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: Clutch problem Reply #13 - 01/02/06 at 13:55:09 Yes, I know. I've had it apart, but maybe I'm a little rusty. There are flats on the shaft for the #24. Isn't #27 a snap ring and #26 a spring?
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torque Serious Thumper 2005 No Login Offline 2008 nightster,flat od green and black Posts: 748 rock hill,S.C. Gender:	Re: Clutch problem Reply #14 - 01/02/06 at 13:59:11 #27 is just a washer,#26 is a spring
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