Bender
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SuzukiSavage.com Rocks!
Posts: 20
SF Bay Area, CA
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I'd like to add another data point to this forum. I bought my 2009 S40 a few weeks ago with 14,500 miles, and a clutch that slips above 30 mph. The clutch seemed like it was barely engaging from a stop, I could put the bike in 1st, release the clutch lever, and it wouldn't stall, but I could give it throttle and it would go.
I did not observe where the clutch release arm was adjusted to before I started the work. I opened the clutch cover, and took out the 45.5mm push rod, and put in the long 46.5mm push rod, based on the information I found in the first few pages of this thread. Buttoned everything up, and started the bike, and clutch would not engage at all. I shifted it into 1st, released the clutch lever, and bike sat idling and stationary, in 1st. I tried it in 2nd and same thing. So the clutch was keeping the engine and transmission separate constantly, and now it was worse than before.
I now observed that the clutch release arm was at the bottom mark. I opened up the clutch cover, and put in the short 44.5mm push rod. I closed it all up, and now the clutch release arm was pointing almost to the top mark. I started the bike up, put it in 1st, and as I released the clutch lever, I felt it begin to pull immediately. I took it out on a ride and it it felt like a new clutch.
As stated in the last few pages of this thread, check where you clutch release arm is pointing before you decide to change out the push rod for a different length. For me the clutch release arm was pointing to the bottom mark, and I changed it for a shorter push rod, and that completely fixed the issue.
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