SuzukiSavage.com - proper clutch cable adjustment?

YoungSavage Junior Member Offline everyone knows I'm home by the KA-POW! Posts: 89 Monterey, California Gender:	proper clutch cable adjustment? 05/15/14 at 11:38:18 Has anybody documented a proper how to for all clutch cable adjustments? Don't find anything in the tech section. Even through the list under clutch. YS.
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justin_o_guy2

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Re: proper clutch cable adjustment?
Reply #1 - 05/15/14 at 12:07:28

If its way outta whack you may need to go down to the mount on the engine, but thats kinda rare. Most adjustments can be handled up on the lever. Gotta pull back the rubber & expose the adjusters. One is about 3/4", like a chrome washer with a knurled edge. Gotta get that thing loosened up so the inner part will turn. Adjust the cable so the lever can wiggle about `1/8th inch freely. If its not a little slack the clutch can slip. If its too slack it may not disengage the clutch all the way,

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28768 L.A. California Gender:	Re: proper clutch cable adjustment? Reply #2 - 05/15/14 at 12:35:13 And check with the handlebars turned either way... lock to lock. And check the clutch lever on the tranny. there's 2 marks behind the lever... should be between them.
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YoungSavage Junior Member Offline everyone knows I'm home by the KA-POW! Posts: 89 Monterey, California Gender:	Re: proper clutch cable adjustment? Reply #3 - 05/15/14 at 19:37:20 Thanks guys. Yeah after reading through here the past year and being somewhat mechanically inclined I've got the basics. Just curious if somebody put together an "if this is this way, then ...." doesn't seem as such though.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: proper clutch cable adjustment? Reply #4 - 05/15/14 at 22:20:05 The reason for that is,, its just so danged easy.. Youll be fine. yoUVE GOT ALL THE INFO A GUY COULD NEED.. OOps,, caplox. sorry
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WD Serious Thumper 2005 No Login Offline Professional "scooter trash". Posts: 5207 Rosemark TN Gender:	Re: proper clutch cable adjustment? Reply #5 - 05/16/14 at 00:12:11 Don't forget to lube it before you adjust it... once the strands dry out, the cable can cause all sorts of "fun", "neat", more like annoying, quirks to occur. Do the rear brake cable at the same time. Gear oil, until it oozes out the end of the housing. Takes a while, but worth it.
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LS650THUMPER Junior Member Offline SuzukiSavage.com Rocks! Posts: 64 Ma Gender:	Re: proper clutch cable adjustment? Reply #6 - 05/22/14 at 18:14:56 clutch works but when lever is released seems like it is not tight enough. have to nudge with my fingers to get lever back to rest position. would adjustment at case be the issue. knurled knobs are almost backed out as far as needed.
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Steve H

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Re: proper clutch cable adjustment?
Reply #7 - 05/22/14 at 19:57:46

There should be a nickel's width of free play or maybe just a little more at the perch to make sure. That way you'll know it's engaging all the way. I find that usually the vibration will move mine right back the tiny little way that is left to go.

You can back out on it a little at the case and then go in some with the knurled adjuster at the handle.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: proper clutch cable adjustment? Reply #8 - 05/22/14 at 22:00:55 It shouldnt go all the way out when ya let go. It SHOULD always go the same amount. It should be able to move in & out w/o any effort a little. Like the guy said, if you can use the end of your little finger & puch the lever "in" & slip a nickel in the gap where the lever meets the perch, youre on,,
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Andy RN Full Member Offline Posts: 107 Eugene, OR Gender:	Re: proper clutch cable adjustment? Reply #9 - 04/16/19 at 19:59:45 verslagen1 wrote on 05/15/14 at 12:35:13: And check with the handlebars turned either way... lock to lock. And check the clutch lever on the tranny. there's 2 marks behind the lever... should be between them. My clutch actuating lever (near the tranny) is just above the top line. What should I do?
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verslagen1

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Re: proper clutch cable adjustment?
Reply #10 - 04/16/19 at 20:20:15

Andy RN wrote on 04/16/19 at 19:59:45:

verslagen1 wrote on 05/15/14 at 12:35:13:

And check with the handlebars turned either way... lock to lock.

And check the clutch lever on the tranny.
there's 2 marks behind the lever... should be between them.

My clutch actuating lever (near the tranny) is just above the top line. What should I do?

You need to install a longer throw out rod. they come in 3 sizes, get all 3 and don't worry about what size you need.

22-1
ROD, CLUTCH PUSH (L:44.5MM)
23111-24B00-445
$4.35
22-2
ROD, CLUTCH PUSH (L:45.5MM)
23111-24B00-455
$4.35
22-3
ROD, CLUTCH PUSH (L:46.5MM)
23111-24B00-465

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Andy RN Full Member Offline Posts: 107 Eugene, OR Gender:	Re: proper clutch cable adjustment? Reply #11 - 04/16/19 at 20:23:35 Thanks, Verslagen. So is it pointless to try and make adjustments at the tranny? Also, the bike only has 12K miles on it. My previous Savage never had this problem - even though I rode to to 45K (before the cam chain tensioner broke)... Any thoughts on why the clutch push rod would be failing?
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28768 L.A. California Gender:	Re: proper clutch cable adjustment? Reply #12 - 04/16/19 at 21:56:15 the clutch rod can wear the cable can stretch the discs can wear or the basket can wear.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28768 L.A. California Gender:	Re: proper clutch cable adjustment? Reply #13 - 04/16/19 at 22:28:23 Install the longest one you can without compressing the clutch when you tighten down the cover. Measure how long the rod sticks out of the pack, 12.5mm is what I strive for.
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Andy RN

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Re: proper clutch cable adjustment?
Reply #14 - 04/17/19 at 17:37:12

verslagen1 wrote on 04/16/19 at 21:56:15:

the clutch rod can wear
the cable can stretch
the discs can wear
or the basket can wear.

Gotchya. I just think it's peculiar that this happened after so few miles on this bike, and didn't happen on my previous Savage. Again, thanks for the info - now I have to scour Clymer's so I can perform this operation.

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US Navy (99-03). Novice, self-taught mechanic. 2003 Savage with 44k miles. 2015 S-40 with 5k miles.

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