SuzukiSavage.com - Clutch cable replacement problems

ajhoff83

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Clutch cable replacement problems
07/09/13 at 18:34:17

So I hope I can get this across to make sense;

The adjustment screw on my clutch lever broke so I decided to replace it and the whole clutch cable for good measure. Got the correct cable and put it on today. No amount of adjustment on either ends of the cable will make it taught. Isn't there supposed to be some resistance from the lever on the engine? Meaning that when I let go of the clutch lever it doesnt pull back out to an open position. Right now i can only get the clutch lever to go back out my pushing it.

On a possibly related note the little lever that goes from the cable to the engine spins free clockwise and counter-clockwise. I could spin it forever if I wanted. Is it supposed to do that? It provides no pull on the cable at all. Is the clutch destroyed or something?

I know about a medium level of mechanical knowhow so any help would be appreciated! thanks!

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justin_o_guy2

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Re: Clutch cable replacement problems
Reply #1 - 07/09/13 at 18:44:34

how did you prove to yourself you have the right cable?

On a possibly related note the little lever that goes from the cable to the engine spins free clockwise and counter-clockwise. I could spin it forever if I wanted. Is it supposed to do that? It provides no pull on the cable at all. Is the clutch destroyed or something?

thats not a good sign.. gonna hafta go in there,,

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Single_Spark Junior Member Offline Here goes nothing... Posts: 51 Portland, OR Gender:	Re: Clutch cable replacement problems Reply #2 - 07/09/13 at 18:52:42 If the release arm is spinning freely, your release cam inside your clutch confer may have fallen off or be broken. It sits on the end of the rod attached to the arm inside the cover. It looks like this...
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ajhoff83

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Re: Clutch cable replacement problems
Reply #3 - 07/09/13 at 19:10:07

I got the new cable from a motorcycle shop here in Madison who took my VIN number to get it right. It is the exact same as the old cable.

Yeah it definitely spins freely forever.

How difficult is it to replace this release cam? Do I need to drain the oil to do that? I dont need step by step per se but can you give me a short summary of the jist of it?

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Clutch cable replacement problems Reply #4 - 07/09/13 at 19:22:38 yep, drain oil, pull r/ side peg. , exhaust all comes off, 1 piece, no need to pull muffler from header,head/ header crush seal should re-run, probably gonna need a case gasket.. mite wanna replace the clutch shaft o-ring while youre there
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Single_Spark

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Re: Clutch cable replacement problems
Reply #5 - 07/09/13 at 19:40:29

You might think about getting the other pushrods, too. A lot people here have gone with the longer one.

Also, check the cam chain tension adjuster while you're in there. Those things are known to fail quickly. Someone on this board put it best when they said it's like having a grenade between your legs. That's what originally failed on mine.

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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18098 Camp Springs, Kentucky Gender:	Re: Clutch cable replacement problems Reply #6 - 07/10/13 at 10:19:19 You might also consider adding where you live to your CPanel. That way if someone live close by and can help......they might contact you and offer to help.
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ajhoff83

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Re: Clutch cable replacement problems
Reply #7 - 07/12/13 at 21:24:16

so i popped the cover off and the release cam was broken in 3 pieces.almost fell deeper into the engine! ordered a new one plus spring and everything that goes along with that part. Also a new cam chain adjuster.

SO what way does this cam release go on once I get it? I see theres a flat part that matched the rod on the inside of the cover. BUT does that little dimple go up down?

thanks so much!

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Clutch cable replacement problems Reply #8 - 07/12/13 at 21:36:02 dimple/rod why you need adjuster? get one from verslagen, avoid problems
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keith YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 37	Re: Clutch cable replacement problems Reply #9 - 07/13/13 at 01:31:34 Looks like it is the week for clutch releases breaking, mine broke today.
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ajhoff83 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 25 Madison, WI Gender:	Re: Clutch cable replacement problems Reply #10 - 07/13/13 at 05:08:36 i measured the play in the adjuster and its more than the .71" that it should be (its actually 1.24"). Figured while it was open might as well do this. I just dont know what was that little cam release tab is supposed to go. See the picture earlier in this thread for reference.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Clutch cable replacement problems Reply #11 - 07/13/13 at 05:28:21 that thing pushes on the rod in the clutch , so, dimple/rod
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WD Serious Thumper 2005 No Login Offline Professional "scooter trash". Posts: 5207 Rosemark TN Gender:	Re: Clutch cable replacement problems Reply #12 - 07/13/13 at 08:46:25 Dimple is on the bottom side, pretty sure, just put my cover back on yesterday. Sans new tensioner, I might have enough left in mine to make it to the get together in Sept... glad it is close (at my place)...
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