SuzukiSavage.com - Pretty sure clutch is fried, this the right kit?

KaleoAlakai YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 21	Re: Pretty sure clutch is fried, this the right ki Reply #15 - 09/18/15 at 15:09:16 To answer both questions: They both have a small amount of resistance. To pull the clutch lever in you feel a slight force. When I pull the clutch arm up to there is a slight force, until of course the clutch lever is at the handlebar.
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youzguyz

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Re: Pretty sure clutch is fried, this the right ki
Reply #16 - 09/18/15 at 15:49:10

KaleoAlakai wrote on 09/18/15 at 15:09:16:

When I pull the clutch arm up to there is a slight force, until of course the clutch lever is at the handlebar.

Time to define some things here, and show how they work. If this sounds a bit too condescending, I apologize.

Referring back to this picture:
http://www.ronayers.com/oemparts/a/suz/50d32fb6f8700232d0b3d922/clutch

#24 is the clutch arm. Disconnect the cable from the arm. There is a little piece of metal you bend open, then slip the cable out of the clip.

When that is done, the only resistance on the arm comes from inside the engine case.

Spring #25 is weak. It is only there to keep tension on the cable.
The clutch springs (#15) are very strong.

When you (or the cable) pulls up on the arm, the cam (#23) pivots, pushes on the rod (#22) which is resisted by the clutch springs (#15) and that allows the plates to separate, disengaging the clutch so you can shift gears. Pushing that rod in takes a LOT of force.
If you can lift that lever up by hand at all, you are either one very strong dude (gal?).. or there is a problem inside the case.

SO, if you have only slight resistance on the arm when you lift, then either the cam is broken, the rod is broken, or the clutch basket (where the strong springs are) is broken. You won't know what is going on until you take off the clutch cover.
The small resistance you are feeling is just spring #25

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2002 - Silver (Thumper)
2000 - Green (Mad Hamish)
Most motorcycle problems are caused by the nut between the seat and the handlebars. Make sure yours isn't too tight or too loose.

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KaleoAlakai YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 21	Re: Pretty sure clutch is fried, this the right ki Reply #17 - 09/18/15 at 16:01:35 Not condescending at all, I am absolutely new to the clutch side of things here. How would I take the clutch cover off?
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KaleoAlakai YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 21	Re: Pretty sure clutch is fried, this the right ki Reply #18 - 09/18/15 at 16:05:38 Okay. I can't lift the clutch arm past it's position. Maybe a millimeter.
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KaleoAlakai YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 21	Re: Pretty sure clutch is fried, this the right ki Reply #19 - 09/18/15 at 16:09:58 Update: I removed the cable from the clutch arm, and can lift the clutch arm to the stopping point(?). About 30 degrees.
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springman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2217 Spring, Texas Gender:	Re: Pretty sure clutch is fried, this the right ki Reply #20 - 09/18/15 at 16:13:34 Youzguyz, your explanation was great, not condescending. Thanks. I am just following along to try to learn myself.
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youzguyz

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Re: Pretty sure clutch is fried, this the right ki
Reply #21 - 09/18/15 at 16:30:24

KaleoAlakai wrote on 09/18/15 at 16:09:58:

Update: I removed the cable from the clutch arm, and can lift the clutch arm to the stopping point(?). About 30 degrees.

Then it sure sounds like you have problems inside.

A Clymers manual and these two threads will help you get the clutch cover off.

http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1191167029

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1256079122

Good luck!!

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2002 - Silver (Thumper)
2000 - Green (Mad Hamish)
Most motorcycle problems are caused by the nut between the seat and the handlebars. Make sure yours isn't too tight or too loose.

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KaleoAlakai YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 21	Re: Pretty sure clutch is fried, this the right ki Reply #22 - 09/18/15 at 18:05:58 Thanks, you've been a great help Youzguyz. I guess all I can ask is if you think this would benefit from getting the clutch rebuild kit?
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KaleoAlakai YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 21	Re: Pretty sure clutch is fried, this the right ki Reply #23 - 09/18/15 at 19:07:38 Or could it just be the push rod?
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youzguyz Serious Thumper Offline Posts: 2538 San Antonio, Texas Gender:	Re: Pretty sure clutch is fried, this the right ki Reply #24 - 09/19/15 at 05:59:00 I really doubt you will need that expensive clutch kit. My first bet would be the cam. No way to know until you open it, and the only part you will need for sure at this point is the clutch cover gasket. Once you know what you need, you buy it.
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KaleoAlakai YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 21	Re: Pretty sure clutch is fried, this the right ki Reply #25 - 09/19/15 at 13:21:02 How expensive of a job is the cam if I take it into a shop? Also, I have a 95 suzuki savage engine (that was blown). Would I be able to use any of the parts from it for this?
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HovisPresley

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Good Vibrations!

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Re: Pretty sure clutch is fried, this the right ki
Reply #26 - 09/19/15 at 13:36:58

Really, don't take it to a shop....

We can guide you through it, it's an easy job, it won't cost a fortune.

Read all the relevant bits from the Tech Section, be prepared to take a few photos on your phone and share them using photobucket/tinypic/etc.

Above all, don't sweat, this forum is a deep well of knowledge that prides itself in it's ability to be of help Wink

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'96 Bobbobbobber

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youzguyz

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Re: Pretty sure clutch is fried, this the right ki
Reply #27 - 09/19/15 at 14:01:31

KaleoAlakai wrote on 09/19/15 at 13:21:02:

How expensive of a job is the cam if I take it into a shop?

Also, I have a 95 suzuki savage engine (that was blown). Would I be able to use any of the parts from it for this?

Labor is expensive. The parts are not. The cam is $6.44. The expensive part is the gasket, and you won't be able to reuse that unless you are very lucky when opening up the case.

Yes, you could probably use the parts from the 95 engine. You can test that theory by going to that link (yes, again) and clicking on the part. It will show you which years it applied to.
I.E. I click on that Cam (#23) link, and I get this:
http://www.ronayers.com/oemparts/p/suzuki/23263-24b01/cam-release

Hey presto.. the same part is used from 1986 to 2015 !!

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2002 - Silver (Thumper)
2000 - Green (Mad Hamish)
Most motorcycle problems are caused by the nut between the seat and the handlebars. Make sure yours isn't too tight or too loose.

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justin_o_guy2

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What happened?

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East Texas, 1/2 dallas/la.

Re: Pretty sure clutch is fried, this the right ki
Reply #28 - 09/19/15 at 19:44:31

That is made of sintered metal.Mine broke, at low speed, thankfully. Messed up a cam chain guide. We've seen a few go.
It's easy to fix.
The oring the clutch arm passes through is almost free, and you're gonna be right there. Mine leaked,,,
You don't need to get it from the dealership. A hydraulics parts shop, good hardware store..
Just get the right sealant. Be conservative, thin and even.
This is a great opportunity, you'll get some experience and the money you'll save will pay for the tools and parts and your confidence will grow.

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KaleoAlakai YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 21	Re: Pretty sure clutch is fried, this the right ki Reply #29 - 09/20/15 at 02:01:07 Alright, then when I pick up my old engine from my old town, I can get to work on all this. Thanks for the help guys, and I will be asking for your guidance through this when I start!
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