SuzukiSavage.com - Torque Specs?

Jonny_Chicago

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Posts: 513
Chicago, IL
Gender: male

Torque Specs?
06/09/08 at 09:58:23

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Ok, so I was riding the savage the other day and bout 45 minutes from my house the clutch gives out (I was unable to engage the clutch). I had to shift back home without a clutch! (this is not the first time clutch cable has gone; on the expressway in Chicago, the cable broke! now that was scary!)

Anyway, when I got home I noticed the clutch cable was NOT broken. The clutch lifted the lever that goes into the engine like it is suppose. However, there was free play when I pulled the clutch down. There was no tension. I blew every stop sign and red light to get home, so I didnt have to down shift without a clutch.

Any suggestions as what could be wrong? Transmission? I have a feeling this is going to be more expensive to fix than a broken clutch cable :'(

Any input is much appreciated

Thank you for taking the time to read my problem

Thanks again
Jonny

P.S. If I was not clear on anything let me know

Thanks again!

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« Last Edit: 06/17/08 at 10:56:02 by Jonny_Chicago »

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?! Reply #1 - 06/09/08 at 10:06:29 I believe there is a pin that connect the exterior lever and shaft to a cam on the inside of the clutch cover. It could be sheared.
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Jonny_Chicago Serious Thumper Offline Nazis, f**k off! Posts: 513 Chicago, IL Gender:	Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?! Reply #2 - 06/09/08 at 10:09:43 If I take the clutch cover off is there oil in there?
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youzguyz Serious Thumper Offline Posts: 2538 San Antonio, Texas Gender:	Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?! Reply #3 - 06/09/08 at 10:17:20 Yep, sure is. Best bet is to drain the oil. 2nd best bet is to lean bike WAY over/ Be very, very, careful, and you might be able to salvage the clutch cover gasket for re-use.
Back to top	2002 - Silver (Thumper) 2000 - Green (Mad Hamish) Most motorcycle problems are caused by the nut between the seat and the handlebars. Make sure yours isn't too tight or too loose. IP Logged

youzguyz Serious Thumper Offline Posts: 2538 San Antonio, Texas Gender:	Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?! Reply #4 - 06/09/08 at 10:20:14 Here is the pieces: Clutch Parts The pin verslagen is talking about is #22
Back to top	2002 - Silver (Thumper) 2000 - Green (Mad Hamish) Most motorcycle problems are caused by the nut between the seat and the handlebars. Make sure yours isn't too tight or too loose. IP Logged

Max_Morley Serious Thumper Offline LT650 Luxury Touring & sidecar rig Posts: 1490 Moses Lake. WA Gender:	Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?! Reply #5 - 06/09/08 at 18:01:24 The part that broke on me is 21 the clutch cam. It is just a cast piece and broke in two pieces. Max
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?! Reply #6 - 06/09/08 at 20:16:52 I've done the lean over trick, it works.
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Jonny_Chicago Serious Thumper Offline Nazis, f**k off! Posts: 513 Chicago, IL Gender:	Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?! Reply #7 - 06/10/08 at 10:35:55 What's the difference between the three different kinds of #22 in that diagram?
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?! Reply #8 - 06/10/08 at 11:14:34 did you take it apart yet? As to what part #... 28 not 22. Don't really know, but would assume years
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youzguyz Serious Thumper Offline Posts: 2538 San Antonio, Texas Gender:	Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?! Reply #9 - 06/10/08 at 11:30:28 verslagen1 wrote on 06/10/08 at 11:14:34: did you take it apart yet? As to what part #... 28 not 22. Don't really know, but would assume years My mistake.. I thought verslagen meant the push pin (#22), not that cotter pin (#28).
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Jonny_Chicago Serious Thumper Offline Nazis, f**k off! Posts: 513 Chicago, IL Gender:	Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?! Reply #10 - 06/10/08 at 18:39:48 Ok, I have not taken it apart yet. Just ordered the parts. Thanks all for the useful help! Thanks again. I will keep you guys posted on updates!
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?! Reply #11 - 06/10/08 at 18:54:52 if you haven't taken it apart, how'd you know what needs fixin?
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Jonny_Chicago Serious Thumper Offline Nazis, f**k off! Posts: 513 Chicago, IL Gender:	Re: PROBLEM, PLEASE HELP; FREE PLAY IN CLUTCH!?! Reply #12 - 06/11/08 at 00:36:14 Guessed? Plus you guys gave me some input on the problem. Hoping it is not more than just the pin. Plus the cotter pin is only $.68. If it is more of a headache I will be crawling back to ask more questions. I will keep you guys posted. Thanks again!
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Jonny_Chicago

Serious Thumper

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Nazis, f**k off!

Posts: 513
Chicago, IL
Gender: male

Re: UPDATE, PLEASE HELP; Its the release cam.
Reply #13 - 06/16/08 at 19:19:10

Well, I guessed wrong. When I got the case off it turned out to be the Release Cam in the Clutch Assembly (#5). It was broke in two. I guess thats my fault for driving it like I stole it a.k.a. driving like sh*t.

Do you guys know what torque spec to set on the bolts?

Also, any further advice at all is much appreciated!

Thanks again, you guys are great!

Jonny

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Jonny_Chicago Serious Thumper Offline Nazis, f**k off! Posts: 513 Chicago, IL Gender:	Re: Torque Specs? Reply #14 - 06/17/08 at 10:52:44 P.S. Thought I would use this same topic so I didnt have to start a new one.
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