SuzukiSavage.com - How hard is replacing the clutch disks?

Toymaker Serious Thumper Offline Dragon Rider Posts: 1534 Granite Falls, NC Gender:	How hard is replacing the clutch disks? 12/29/08 at 11:40:27 inquiring minds want to know.... and mine too.
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verslagen1

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Re: How hard is replacing the clutch disks?
Reply #1 - 12/29/08 at 12:06:33

Almost the same as a clutch chain adjuster check.
Just 4 more bolts to get at the disks.
Hard part is getting it back together right.
check operation before filling with oil.
sometimes the disks get hung up on the basket.
Or the spring ring isn't aligned.
I don't know which was my problem, but taking it loose and shifting things around a bit was enough to set it right.

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Oldfeller--FSO

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Re: How hard is replacing the clutch disks?
Reply #2 - 12/29/08 at 12:35:16

Take a pic or write a little detailed drawing to yourself on the exact order of components and specific notes on orientation of plates and rings when you take it apart.

More than several have screwed up the order of reassembly and orientation of the spring ring, ect. because it looked "so easy" they didn't take any note of anything in particular on the teardown side.

Clymers isn't clear enough to put it back right, neither is the exploded diagrams on line.

Remember to save your old friction discs ...

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Oldfeller--FSO Serious Thumper ModSquad Offline Hobby is now "concentrated neuropany" Posts: 12671 Fayetteville, NC Gender:	Re: How hard is replacing the clutch disks? Reply #3 - 12/29/08 at 12:45:54 Do we have a Tech Section detailed post on how to "replace your clutch" yet? Maybe that little pink camera can take some pics and you can be the first Savager to go "in a tight clutch" and to record all the holds, tricks and such to wrassle that little clutch box into submission.
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saluteTOme

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Re: How hard is replacing the clutch disks?
Reply #4 - 12/29/08 at 14:04:33

Oldfeller--FSO wrote on 12/29/08 at 12:45:54:

Do we have a Tech Section detailed post on how to "replace your clutch" yet?

Maybe that little pink camera can take some pics and you can be the first Savager to go "in a tight clutch" and to record all the holds, tricks and such to wrassle that little clutch box into submission.

Wink

please DO! Cheesy

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Toymaker Serious Thumper Offline Dragon Rider Posts: 1534 Granite Falls, NC Gender:	Re: How hard is replacing the clutch disks? Reply #5 - 12/29/08 at 16:11:50 Well, I will prolly do this thing early in the spring. I adjusted the clutch play and it seems I have a bit more than I thought.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: How hard is replacing the clutch disks? Reply #6 - 12/29/08 at 22:40:58 &, if you dont hold the "stirrup" up that the clutch cable connects to, you'll be nhappy, because the only way to swing it up to connect the clutch cable is to unbolt the cover & get it away from the motor, OR bend the crap outta the thing. I bent the Crapp outta mine.
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Re: How hard is replacing the clutch disks?
Reply #7 - 12/30/08 at 06:34:24

I suspect that if you went into it and made up a slightly shorter actuation rod you'd have quite a bit more clutch life to play with.

BTW, measure your rod protrusion "as worn out" and measure it again after you put the new disks into it. The difference is our real stacked pack wear life that our cable adjustment works against.

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Kropatchek Serious Thumper Offline Why more than 1 cylinder? Posts: 1457 Alphen a/d Rijn Netherlands Gender:	Re: How hard is replacing the clutch disks? Reply #8 - 12/30/08 at 07:21:40 And do not forget to soak the new clutch plates 24 hours in engine oil.
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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: How hard is replacing the clutch disks? Reply #9 - 12/30/08 at 07:31:10 Kropatchek wrote on 12/30/08 at 07:21:40: And do not forget to soak the new clutch plates 24 hours in engine oil. Do you have to soak the kevlar plates?
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Re: How hard is replacing the clutch disks?
Reply #10 - 12/30/08 at 11:00:25

Thanks for the tip about soaking them in oil, almost forgot that. As soon as I've got the $ I'll be replacing the plates on my ktm250. they're NOT cheap. The last couple trips we went on I had to pull the cover and separate all the plates and oil them. Not fun in the middle of the desert but it got me riding while we were out. If anyone wants I'll post pix of the job as it's very similar to ours. I know it's not the exact same but I think all clutch baskets should be relatively as simple as this one.

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