SuzukiSavage.com - Can I leave out the clutch wave and seal washer?

gsxboy99

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Can I leave out the clutch wave and seal washer?
04/01/14 at 11:34:56

I'm installing a Barnett clutch and the i had to remove the wave washer to be able to have movement in my clutch basket. with the wave washer in the bike would not disengage the clutch so it wanted to run a way on me, i had to fight the bike holding Flintstones style. so i took the wave out and now it has the movement it needs. now what i want to know is can i take the seal washer out as well. the last kevlar plate pads aren't making contact with the Hub,clutch Sleeve machined surface. so can i take it out and then have it make contact giving me better holding ability? and just make a new push rod to make up for whats gone? i think i'm on to something because if u notices on this site http://www.cmsnl.com/suzuki-ls650-p-savage-1996-2004-usa_model16138/partslist...
it says " The Washer (110.5x119x0.90) appears in these Ls650 P Savage 1996-2004 (usa) parts lists:"
"(usa) parts lists"?!?!?!? we know we get screwed by bikes coming in from over seas w emissions but think these washers are put there for less factory grip, what do you guys thing?

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28757 L.A. California Gender:	Re: Can I leave out the clutch wave and seal washe Reply #1 - 04/01/14 at 12:58:55 I'd have to say... you've rebuilt your clutch wrong. Barnett or otherwise, the stock assembly works. and yes, it can be sticky when assembled or adjusted wrong. Yes, they can be built wrong... http://youtu.be/UmzGblbeDuU
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gsxboy99

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Re: Can I leave out the clutch wave and seal washe
Reply #2 - 04/01/14 at 13:48:21

yeah i put the washers in there wrong for 2 broken release cams :/ till i figured out the washers have the clutch disks jammed and didn't have any movement to disengage. i have them in there now with the flat washer against the hub and the wave washer big side against the other washer and the small side poking towards the inside of the 1st kevlar disk. does this sound rite? it's the only configuration that would let it have movement to disengage.

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28757 L.A. California Gender:	Re: Can I leave out the clutch wave and seal washe Reply #3 - 04/01/14 at 14:04:17 the wave washer goes between 2 steels The flat washer (steel) goes against the aluminum hub. The other steel is the 1st plate. The inside of the wave washer is going to ride on the hub (if I remember correctly) so I put it on the flat washer side.
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gsxboy99 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 17	Re: Can I leave out the clutch wave and seal washe Reply #4 - 04/01/14 at 14:38:16 thx, yup the wave has to poke inside the 1st disk. thx again, for the problem shooting. glad my ish didn't rip apart yikes
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gsxboy99 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 17	Re: Can I leave out the clutch wave and seal washe Reply #5 - 04/01/14 at 18:00:37 but still the one side of the 1st kevlar disk doesn't make contact with the machined surface of the hub, whats that about?
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17808 Camp Springs, Kentucky Gender:	Re: Can I leave out the clutch wave and seal washe Reply #6 - 04/07/14 at 05:54:12 Any update on this? Any way for you to post pictures? I just ordered a set of the Barnett Plates......I will take some photos of the installation and it may help. Dave
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ThumperPaul

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Re: Can I leave out the clutch wave and seal washe
Reply #7 - 12/23/23 at 06:26:25

Dave, I’m dredging up this 9+ year old post…. I want to make sure I have my wave washer orientation correct.

This thing is hard to talk about and photos/sketches really don’t help much. Concave/convex. Which way?

Let me ask it this way - does the smaller diameter of the wave washer point towards the 1st fat fiber disc and the larger diameter of the wave washer point towards the wave washer seat?

Said another way - If the wave washer is a eyeball, it would be looking at you as you placed it against the seat. Right?? Or is the wave washer eyeball looking at the seat?

Also, there is a comment above by Verslagen saying it goes next to a steel plate (seat, wave washer, steel)…. I think it goes against the first fat fiber disc (#1 fiber disc per Clymer).

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28757 L.A. California Gender:	Re: Can I leave out the clutch wave and seal washe Reply #8 - 12/23/23 at 08:31:09 From the FSM...
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ThumperPaul

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Re: Can I leave out the clutch wave and seal washe
Reply #9 - 12/23/23 at 08:36:54

Thanks Verslagen. This is the confusing 2D sketch that I'm trying to gain clarity on.

So the "eyeball" (3D imagination) is looking at the discs. And technically you are correct that the wave washer is against steel on both sides with the #1 fat fiber disc riding over it (or sitting on top of it).

Do I have this correct?

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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1001 Houston, Texas Gender:	Re: Can I leave out the clutch wave and seal washe Reply #10 - 12/23/23 at 08:40:38 And how do you know if the wave washer is dead or losing its punch?
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DragBikeMike

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Re: Can I leave out the clutch wave and seal washe
Reply #11 - 12/23/23 at 10:06:48

Your picture that you provided in your R&R Cylinder Head post shows your wave washer correctly installed. I have marked it up.

The wave washer seat (yellow arrow) goes against the face of the aluminum clutch hub. As previously mentioned, it is there to protect the aluminum face from the sharp edge on the wave washer.

The inside diameter edge of the wave washer (green arrow) goes against the wave washer seat.

The outside diameter edge of the wave washer (red arrow) goes against the first steel clutch plate.

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Wave_Washer_Correct.jpg

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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1001 Houston, Texas Gender:	Re: Can I leave out the clutch wave and seal washe Reply #12 - 12/23/23 at 10:45:55 Thanks Mike! Glad you have good eyesight and lots of patience!
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