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Clutch Replacement Parts (Read 87 times)

Coaxial

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SuzukiSavage.com
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Posts: 184
Toronto, Ontario, Canada
Gender: male

Clutch Replacement Parts
08/24/15 at 07:26:41

Hey Everyone,

I will be undertaking a clutch replacement in a few months. I am gathering items I need.

So far just:
+Friction plates
+Gasket
+Perhaps a new clutch cable just for peace of mind?

And yes I read about how it may not be needed for my bike but due to me being hard on the clutch, learning engine braking. It is slipping and losing power.

I have been always using Rotella T6 and I am now at around 50,000 km and most of it done in a very congested city area. I have tried to adjust the clutch and it did not help. I considered clutch rod, but that seems a bit complex for me, so I will just take on replacing the clutch.

2007 Suzuki Boulevard S40 Black. K&N Air Filter, Jardine Rumbler Exhaust, Raptor Petcock.

145 Main Jet, 45 Pilot Jet, 1.5x

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Dave

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Camp Springs, Kentucky
Gender: male

Re: Clutch Replacement Parts
Reply #1 - 08/24/15 at 07:42:30

Coaxial wrote on 08/24/15 at 07:26:41:

I considered clutch rod, but that seems a bit complex for me, so I will just take on replacing the clutch.

Replacing the clutch rod is less than half as complicated as the replacement of the friction discs.

Is the end of the lever at the engine between the two marks on the case.....when you lightly push up on the lever?

Someday I will be old......But not today!

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Coaxial Full Member Offline SuzukiSavage.com Rocks! Posts: 184 Toronto, Ontario, Canada Gender:	Re: Clutch Replacement Parts Reply #2 - 08/24/15 at 07:53:48 I cannot push up the lever freely. Here is a pic
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Clutch Replacement Parts Reply #3 - 08/24/15 at 08:02:47 looks like it needs a new rod to me. There are two marks on the case behind the lever and you look to be over the top one. There are 3 replacement rods, fairly cheap, get 1 of each. I custom grind mine so I get 12.5mm of rod protruding from the clutch pack.
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Coaxial Full Member Offline SuzukiSavage.com Rocks! Posts: 184 Toronto, Ontario, Canada Gender:	Re: Clutch Replacement Parts Reply #4 - 08/24/15 at 08:12:17 Where would I obtain these rods? I am in Canada fyi.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Clutch Replacement Parts Reply #5 - 08/24/15 at 09:05:50 Coaxial wrote on 08/24/15 at 08:12:17: Where would I obtain these rods? I am in Canada fyi. same place you got your other parts. As an alternate, full hard Ø1/4" dowel pins
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18098 Camp Springs, Kentucky Gender:	Re: Clutch Replacement Parts Reply #6 - 08/24/15 at 09:39:05 The parts are available from the dealer.....part number 22 in the diagram linked below: http://www.hondaofflorence.com/fiche_section_detail.asp?section=82431&categor...
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Coaxial Full Member Offline SuzukiSavage.com Rocks! Posts: 184 Toronto, Ontario, Canada Gender:	Re: Clutch Replacement Parts Reply #7 - 08/24/15 at 14:11:13 Thanks guys, I bought all 3 rods from a local parts store. Will come soon. Which clutch rod is ideal to use?
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Clutch Replacement Parts Reply #8 - 08/24/15 at 14:30:27 The longest one that will fit under the cover w/out activating the clutch. As I said, I shoot for 12.5mm sticking out. 13 is too much, 12 too little.
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