SuzukiSavage.com - Stuck on clutch install

fla-shadow

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Stuck on clutch install
10/16/07 at 20:44:17

Help!! I am stuck on a clutch install. I think that I may have tightened the bolts down to tight on the release plate.

I replaced the clutch plates per the Clymer Manual and I had ZERO pressure on the clutch lever. I removed the engine cover and removed the 4 bolts holding the release plat in place. I looked at the clutch assembly on the bike and in the book. I cannot find anything wrong at this time.

My best guess is that I might not need to tighten the bolts on the release plate all the way down until the bottom out. This may allow the springs assembly to perform some kind of useful function.

Please let me know if there is any secret to tightening down the release plate over the clutch springs. So I tighten them all the way down? If not, then how much room should I leave for the springs to activate and how can I measure it?

Any advice would be greatly appreciated. The Savage is out of commission until I can get this solved.

Thanks,
fla-shadow

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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: Stuck on clutch install Reply #1 - 10/16/07 at 21:04:22 I'm sure the Clymer states a torque value for the release plate bolts...therefore they are tightened all the way down. Did you reinstall the pushrod?
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fla-shadow

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Re: Stuck on clutch install
Reply #2 - 10/16/07 at 21:33:04

I believe that I installed the pushrod. I after re-reading the manual, it appears that I was correct in tightening the bolts over the springs down all of the way. I must have missed something during the install.

I will tear down and re-install the clutch basket tonight. This time I will double check the pictures, diagrams, and instructions in the manual to see make sue the I did not miss anything. I will also check to make sure that I do not have any "extra" or "missing" parts after the install.

I will let you know how it turns out.

Thanks,

Fla-Shadow

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Kropatchek Serious Thumper Offline Why more than 1 cylinder? Posts: 1457 Alphen a/d Rijn Netherlands Gender:	Re: Stuck on clutch install Reply #3 - 10/17/07 at 06:02:20 You probably have installed the oil-pump drive gear, on the back of the clutch-basket, the wrong way around. If so, you're not the first one to do so. Check the Clymers, there's a clear picture of the assembly.
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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: Stuck on clutch install Reply #4 - 10/17/07 at 07:11:40 Oh yeah, good point...if you did install it wrong, you can be glad the clutch doesn't work.
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fla-shadow

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Re: Stuck on clutch install
Reply #5 - 10/17/07 at 17:21:45

I have the clutch working now. My third attempt at re-assembly worked.

I think that the Clymer manual has an error in it. It calls for disc # 1 to have the smallest thickness at 3.00 mm and disc 2 to be larger at 3.5mm. My EBC kit had 5 discs at 3.0 mm and 1 disc at 3.5 mm. When I installed the 3.0 mm disc in the #1 position, it was hitting on the wave washer and preventing the clutch assembly from fully closing. This must have resulted in the pushrod from being further away from the actuator arm and not giving any pressure on the clutch lever.

I measured the old clutch discs that I had already removed and found out that the one unique disc was the thickest, (near 3.5mm), and the other 5 were smaller, (near 3.0mm). Then I cross referenced the EBC part Number to verify that I had the right kit.

Next, I checked out the microfiche on 3 websites to eventually discover that the inside diameter of disc # 1 is supposed to be 120mm and the rest of the discs should be 116 mm. The thickest disc in my kit measured 120 mm, so I tried installing it in position #1. The 120 mm diameter fit past the wave washer and the clutch assembled properly. I only push tested the bike so far. I will finish putting on the exhaust tonight and take it for a test drive tomorrow.

Thanks for reminding me to read the directions. When I took my time on the final assembly, I spent more time on the pictures than on the wording. It took some time to find the error in the book, but the clutch appears to be working properly now.

Thanks,

Fla-shadow

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Savage_Rob

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Re: Stuck on clutch install
Reply #6 - 10/17/07 at 18:20:24

fla-shadow wrote on 12/31/69 at 16:00:10:

I have the clutch working now. My third attempt at re-assembly worked.

I think that the Clymer manual has an error in it. It calls for disc # 1 to have the smallest thickness at 3.00 mm and disc 2 to be larger at 3.5mm. My EBC kit had 5 discs at 3.0 mm and 1 disc at 3.5 mm. When I installed the 3.0 mm disc in the #1 position, it was hitting on the wave washer and preventing the clutch assembly from fully closing. This must have resulted in the pushrod from being further away from the actuator arm and not giving any pressure on the clutch lever.

I measured the old clutch discs that I had already removed and found out that the one unique disc was the thickest, (near 3.5mm), and the other 5 were smaller, (near 3.0mm). Then I cross referenced the EBC part Number to verify that I had the right kit.

Next, I checked out the microfiche on 3 websites to eventually discover that the inside diameter of disc # 1 is supposed to be 120mm and the rest of the discs should be 116 mm. The thickest disc in my kit measured 120 mm, so I tried installing it in position #1. The 120 mm diameter fit past the wave washer and the clutch assembled properly. I only push tested the bike so far. I will finish putting on the exhaust tonight and take it for a test drive tomorrow.

Thanks for reminding me to read the directions. When I took my time on the final assembly, I spent more time on the pictures than on the wording. It took some time to find the error in the book, but the clutch appears to be working properly now.

Thanks,

Fla-shadow

If you determine there is an error in the Clymer manual, please add it to the thread on Clymer errors in the Tech Ref forum.

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SavageWahine Serious Thumper Offline Aloha & Hang Loose Posts: 1553 Beautiful Kauai! Gender:	Re: Stuck on clutch install Reply #7 - 10/17/07 at 19:09:44 I was just about to suggest that! Beat me to it.
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Savage_Greg

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Re: Stuck on clutch install
Reply #8 - 10/17/07 at 22:25:22

fla-shadow wrote on 12/31/69 at 16:00:10:

I have the clutch working now. My third attempt at re-assembly worked.

I think that the Clymer manual has an error in it. It calls for disc # 1 to have the smallest thickness at 3.00 mm and disc 2 to be larger at 3.5mm. My EBC kit had 5 discs at 3.0 mm and 1 disc at 3.5 mm. When I installed the 3.0 mm disc in the #1 position, it was hitting on the wave washer and preventing the clutch assembly from fully closing. This must have resulted in the pushrod from being further away from the actuator arm and not giving any pressure on the clutch lever.

I measured the old clutch discs that I had already removed and found out that the one unique disc was the thickest, (near 3.5mm), and the other 5 were smaller, (near 3.0mm). Then I cross referenced the EBC part Number to verify that I had the right kit.

Next, I checked out the microfiche on 3 websites to eventually discover that the inside diameter of disc # 1 is supposed to be 120mm and the rest of the discs should be 116 mm. The thickest disc in my kit measured 120 mm, so I tried installing it in position #1. The 120 mm diameter fit past the wave washer and the clutch assembled properly. I only push tested the bike so far. I will finish putting on the exhaust tonight and take it for a test drive tomorrow.

Thanks for reminding me to read the directions. When I took my time on the final assembly, I spent more time on the pictures than on the wording. It took some time to find the error in the book, but the clutch appears to be working properly now.

Thanks,

Fla-shadow

I don't even know why the Clymer goes into the thickness of Disk 1 or 2....

Disk 1 is the only one that has a larger ID then all the rest. That is so that it fits over the wave washer.

But since you had them switched around, it makes perfect sense now. Have to remember this for the next time it comes up. No wonder you were asking about whether to tighten the springs all the way down. The stack was too big the other way.

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