SuzukiSavage.com - Help, my clutch just went.

Duane

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Help, my clutch just went.
08/05/09 at 16:17:59

I was on a ride tonight and on my way home I pulled the clutch lever in to down shift and after I let it go it never came back out? Any ideas on what might have gone? The cable is not broke because I can hold the transmission end and pull on it and it moves. It's like a spring some place must have broke. I figured the gurus on here would probably know exactly what broke or came off.

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runwyrlph Serious Thumper Offline Semper ubi sub ubi Posts: 846 pa Gender:	Re: Help, my clutch just went. Reply #1 - 08/05/09 at 16:23:57 so, the clutch is engaged (i.e. you're in gear), but the lever is loose?
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28890 L.A. California Gender:	Re: Help, my clutch just went. Reply #2 - 08/05/09 at 17:03:25 I know exactly what happened to you cause it happened to me. On the inside of the clutch is a cam that pushes the clutch rod in. That snapped in 2. Get a new 1 and it'll be good as new.
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Duane Senior Member Offline Creatively Maladjusted Posts: 335 Terra Plane Gender:	Re: Help, my clutch just went. Reply #3 - 08/05/09 at 17:16:38 Yes it was in gear, I rode home in 3rd gear. Do you have a part number by any chance? Is it going to be a fun job? Have you ever noticed things only break after you fill the tank up?
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runwyrlph Serious Thumper Offline Semper ubi sub ubi Posts: 846 pa Gender:	Re: Help, my clutch just went. Reply #4 - 08/05/09 at 17:25:58 http://www.bikebandit.com/suzuki-motorcycle-ls650-2007-clutch/o/m10380sch527352 part #23 i should let verslagen say for sure , but i think that's the part at least it's not too much $$$
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28890 L.A. California Gender:	Re: Help, my clutch just went. Reply #5 - 08/05/09 at 17:37:58 for sure I was on the freeway when she let go. Fun story, you should read it. Do a search, I sure I posted this before.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Help, my clutch just went. Reply #6 - 08/05/09 at 18:30:11 Get a clutch cover gasket b4 U go in there. Nows a great time to have an eye on the chain tensioner.
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Duane Senior Member Offline Creatively Maladjusted Posts: 335 Terra Plane Gender:	Re: Help, my clutch just went. Reply #7 - 08/06/09 at 09:02:00 It's starting to sound like my season might be over. :'( So you think it's : 23: CAM,CKYTCG RELE 487626-001 $6.38 verslagen1 I'm not too go with the forum search I can't find your story. Can you give me some key words that will help find it?
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verslagen1

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Re: Help, my clutch just went.
Reply #8 - 08/06/09 at 09:44:18

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1247172796/4#4

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1246935676/12#12

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1243041635/8#8

23263-24B01 $5.10 here although bikebandit is usually faster.

http://www.babbittsonline.com/pages/parts/viewbybrand/default.aspx

I'd drop in to your local and find out how much it is there. Shipping from these places can be $15. Way too much for 1 part. At least buy some supplies to go with it.

And don't forget the gasket. I agree with JOG, best to have a gasket on hand. But, if you don't tear the gasket when you open it up, it's reusable. I've reused mine several times already. But it was a new gasket opened several times over 2 years.

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justin_o_guy2

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Re: Help, my clutch just went.
Reply #9 - 08/06/09 at 09:55:04

Man, this is a quick & easy fix. Your season isnt over. IDK how many miles you have on it, but one day you will need a cam chain. If you have the pennies & can afford it right now, it wouldnt be a bad idea to have one on hand. If you DO put one on, soak that thing in oil a while to make sure all the pins are wet, because it takes a while for the "splash" to get it lubed up good.
I have an oil leak where the crank arm goes thru the clutch cover. Wouldnt be a bad idea to replace that O-ring while you have that thing out.

Edit: I have my cam chain soaking in oil in a jar, hanging up on the wall in the shop. It wont be rusty when I need to put it in & it will be oiled thru & thru.
BEARTRAP Warning.

When you put it back together, the part the clutch cable hooks into will swing down & you cant swing it back up once its all bolted together. Hold it up as it goes together. I shafted myself here. I didnt take it apart again, I bent the loop up to get it up & usable.

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verslagen1

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Re: Help, my clutch just went.
Reply #10 - 08/06/09 at 11:24:44

BEARTRAP Warning?

I wouldn't even consider it a end table in the dark warning.

If you happen to install the clutch cover with the hook for the clutch cable in the down position (ouch my toe), operate the clutch lever with a cresant wrench and swing the hook around to the top. Band aide applied.

Just be carefull not to force the lever beyound the stop. Likely what started the crack in your cam in the 1st place.

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photojoe FSO

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Re: Help, my clutch just went.
Reply #11 - 08/06/09 at 11:37:07

Not to hijack the thread, but since the discussion includes removing the clutch case/cover, I'll be doing that myself during my next oil change. I'm over 20K and want to take a look at my tensioner.

Outside of a steady hand and new gasket, is there anything else I may need to know with regard to simply removing the cover and replacing the gasket? It is as simple as draining the oil, removing the cover taking care of what I need to do and buttoning back up?

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28890 L.A. California Gender:	Re: Help, my clutch just went. Reply #12 - 08/06/09 at 11:49:27 Take a look in the tech section for the adjuster check procedure. Yeah, it's that easy. you'll need to remove the header too. And you don't even have to drain the oil if you don't want to. I've done this a few times w/o draining the oil. Just tip it to one side about 45°. And it makes it easier to work on too.
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Duane Senior Member Offline Creatively Maladjusted Posts: 335 Terra Plane Gender:	Re: Help, my clutch just went. Reply #13 - 08/06/09 at 12:07:23 My bike is just under 18K I think. So I need to inspect the cam chain while I'm in there? It is a 2003 if that makes any diffrence. I have to fix the blower in my wifes Pontiac before I can start on fixing my transmission. You guys make is sound like it will just take a couple hours.
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justin_o_guy2

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Re: Help, my clutch just went.
Reply #14 - 08/06/09 at 12:08:50

verslagen1 wrote on 08/06/09 at 11:24:44:

BEARTRAP Warning?

I wouldn't even consider it a end table in the dark warning.

If you happen to install the clutch cover with the hook for the clutch cable in the down position (ouch my toe), operate the clutch lever with a cresant wrench and swing the hook around to the top. Band aide applied.

Welll, POOT! Why didnt I see that? Dooooh,, now I feel silly,
Just be carefull not to force the lever beyound the stop. Likely what started the crack in your cam in the 1st place.

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