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Serious Thumper 2005 No Login
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Professional "scooter trash".
Posts: 5207
Rosemark TN
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Went and read it back over. If fiddling with the cable does nothing, time to open her up. Check the springs, and if they are tight, tear the clutch apart. Sounds like you glazed a steel or wiped a fiber, but you could also have a failing "paddle" where the cable arm actuates the pushrod. If you were on a bike with a "normal" metric single spring clutch (VN1500 and such), it would be easy, the spring got chewed up. The 1960s clutch in a Savage is an entirely different design, miniaturized Harley Davidson crossed with Honda locating tangs.
The factory clutch discs are crap. The same cheap fibers and cut rate steels you would find in an Emgo kit. If you ride the bike like a sedate little cruiser, they last a long time, but if you get spirited, especially running lightweight synthetic oil, they'll give up the ghost. I ran fresh Rotella T6 5W40 in my 03 for one day, commuted to work and back home, and changed it out for Rotella 15W40. This makes 2 Savages for me that do not like synthetic oil. Clutch issues, noisy valve train, leaks...
Pop both outer cases off, flush the clutch assembly with contact cleaner, and take it apart. Stuff rags in the big inner case passages so you don't lose any hardware into the transmission.
Clutches, like batteries, either work or they don't.
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