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

KaleoAlakai YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 21	Pretty sure clutch is fried, this the right kit? 09/18/15 at 01:30:34 1995 Suzuki Savage ls650 2003 Engine Is this the right clutch kit? Moreover, is it decent or do you recommend one that you agree to be better? http://www.ebay.com/itm/like/371038783368?ul_noapp=true&chn=ps&lpid=82
Back to top	IP Logged

Dave

YaBB Moderator
ModSquad

Offline

SuzukiSavage.com
Rocks!

Posts: 18099
Camp Springs, Kentucky
Gender: male

Re: Pretty sure clutch is fried, this the right ki
Reply #1 - 09/18/15 at 03:58:41

As the clutch wears, the adjustment available is not sufficient to account for the wear....without using a shorter rod. Suzuki offers 3 different sizes of rods, and more than likely you just need to install a different length rod. Here is a link to a long clutch discussion.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1270678838/0

I have not heard anyone on this site install the Kevlar discs.....not sure if they are any better than the stock discs on this bike.

Back to top

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

IP Logged

KaleoAlakai

YaBB Newbies

Offline

SuzukiSavage.com
Rocks!

Posts: 21

Re: Pretty sure clutch is fried, this the right ki
Reply #2 - 09/18/15 at 12:33:22

Ah well, the clutch started slipping a while ago. (at 21,000 miles). Then it started only shifting without using the clutch lever at all. Now, you can start up the bike without even pulling in the clutch lever (meaning it's always engaged) and when you pull it in and try to shift while hte bike is running it will just shut off.

Overnight it went from average play to completely loose. I've adjusted it as much as possible to tighten it, but it only sits at an inch away from the handlebar.

Back to top

IP Logged

youzguyz

Serious Thumper

Offline

Posts: 2538
San Antonio, Texas
Gender: male

Re: Pretty sure clutch is fried, this the right ki
Reply #3 - 09/18/15 at 12:56:25

This is sounding more like a cable problem than a clutch problem.

The bike won't start unless you pull in the clutch, UNLESS someone disabled that interlock switch that is on the clutch LEVER.

When you say "it will just shut off", does it STALL out? or does it act like someone turned off the key? If the latter, it means the kickstand is down. You can't put the bike in gear with the kickstand down UNLESS someone disabled that interlock as well.

Maybe I am just reading your posts all kinds of wrong? Undecided

Back to top

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.

IP Logged

KaleoAlakai YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 21	Re: Pretty sure clutch is fried, this the right ki Reply #4 - 09/18/15 at 12:59:06 Haha, no I make sure the kickstand is up. Better be thorough though, so yeah. Other than that, it doesn't seem like the cable is damaged or strained at all.
Back to top	IP Logged

KaleoAlakai

YaBB Newbies

Offline

SuzukiSavage.com
Rocks!

Posts: 21

Re: Pretty sure clutch is fried, this the right ki
Reply #5 - 09/18/15 at 13:01:23

And it stalls, sorry about that. I'll kick it into first (which I shouldn't be doing because I can hear myself grind the gears as I do so) with the clutch pulled in and it will just lurch forward and shut off. (stalling)

To add to that, yes. I find it very odd. The bike can start without pulling the clutch in at all, but not when I have the clutch pulled to the handlebar. As if it were reversed.

Back to top

IP Logged

youzguyz

Serious Thumper

Offline

Posts: 2538
San Antonio, Texas
Gender: male

Re: Pretty sure clutch is fried, this the right ki
Reply #6 - 09/18/15 at 13:10:14

Try to move the clutch arm where it goes into the engine.
It would normally take a good size wrench fitting over the arm to move it .
If it moves freely very much, then you have a problem inside the case.

Now I am thinking a busted cam. Especially because it went out "overnight". It could be that the basket has come apart as well, but not as likely.

#23 in this picture
http://www.ronayers.com/oemparts/a/suz/50d32fb6f8700232d0b3d922/clutch

Back to top

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.

IP Logged

verslagen1

YaBB Moderator
ModSquad

Offline

Where there's a
will, I want to be
in it.

Posts: 28886
L.A. California
Gender: male

Re: Pretty sure clutch is fried, this the right ki
Reply #7 - 09/18/15 at 13:16:59

KaleoAlakai wrote on 09/18/15 at 12:33:22:

Ah well, the clutch started slipping a while ago. (at 21,000 miles).
1.Then it started only shifting without using the clutch lever at all.
2.Now, you can start up the bike without even pulling in the clutch lever (meaning it's always engaged)
3.and when you pull it in and try to shift while hte bike is running it will just shut off.
4.Overnight it went from average play to completely loose.
5.I've adjusted it as much as possible to tighten it, but it only sits at an inch away from the handlebar.

five completely confusing statements.
1. I assume it's lurching between shifts, huge clunk, whoops I've done it again?
2. In neutral, kickstand up?
3. Huge lurch and stall?
4. Did you drop it?
5. tight as you can get it and the lever is only an inch away? you did drop it and bent the lever? should be a couple of inches away from the bar when there's no freeplay.

I'm thinking along the same lines as Youzguyz.

Back to top

Versey's Place
Tech Section Index

IP Logged

KaleoAlakai YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 21	Re: Pretty sure clutch is fried, this the right ki Reply #8 - 09/18/15 at 13:33:20 I didn't drop it. The clutch arm does move fairly freely, but that's because of all the play still on the clutch. (Other than that, I have no idea what I am talking about). If it's a busted cam, would a clutch rebuild still benefit from this?
Back to top	IP Logged

KaleoAlakai YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 21	Re: Pretty sure clutch is fried, this the right ki Reply #9 - 09/18/15 at 13:49:04 Because I thought if the cam as busted, the bike just wouldn't start?
Back to top	IP Logged

verslagen1

YaBB Moderator
ModSquad

Offline

Where there's a
will, I want to be
in it.

Posts: 28886
L.A. California
Gender: male

Re: Pretty sure clutch is fried, this the right ki
Reply #10 - 09/18/15 at 13:58:17

KaleoAlakai wrote on 09/18/15 at 13:33:20:

I didn't drop it. The clutch arm does move fairly freely, but that's because of all the play still on the clutch. (Other than that, I have no idea what I am talking about).

If it's a busted cam, would a clutch rebuild still benefit from this?

If the lever is moving freely, no effort to pull the clutch in, then you aren't pulling in the clutch only moving the lever. Check the lever on the clutch case, can you move that freely too?

If you can, then most likely your cam is busted and you'll need to replace it.

Back to top

Versey's Place
Tech Section Index

IP Logged

KaleoAlakai YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 21	Re: Pretty sure clutch is fried, this the right ki Reply #11 - 09/18/15 at 14:13:56 I apologize if this is incorrect. as I have never done any clutch work before but I went ahead and pulled the clutch in and then tried to pull the clutch arm and it wouldn't budge.
Back to top	IP Logged

HovisPresley

Serious Thumper

Offline

Good Vibrations!

Posts: 991
Midlands, UK
Gender: male

Re: Pretty sure clutch is fried, this the right ki
Reply #12 - 09/18/15 at 14:15:47

The cut-out switch is at the lever on the h/bar, rather than inside the right hand case.

Is it a case of;
1. the clutch cut-out has been disabled previously and
2. there has been some failure in the clutch operating mechanism, ie the cam, pushrod etc, (rather than a clutch plate/spring problem)?

It's a simple job to take of the r/h/s cover to check out the mechanism, but I'm sure there will be something recognisably wrong as soon as you see it

Back to top

'96 Bobbobbobber

IP Logged

KaleoAlakai YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 21	Re: Pretty sure clutch is fried, this the right ki Reply #13 - 09/18/15 at 14:33:41 I have no idea how to take off the clutch cover.
Back to top	IP Logged

verslagen1

YaBB Moderator
ModSquad

Offline

Where there's a
will, I want to be
in it.

Posts: 28886
L.A. California
Gender: male

Re: Pretty sure clutch is fried, this the right ki
Reply #14 - 09/18/15 at 14:33:55

KaleoAlakai wrote on 09/18/15 at 14:13:56:

I apologize if this is incorrect. as I have never done any clutch work before but I went ahead and pulled the clutch in and then tried to pull the clutch arm and it wouldn't budge.

No, do 1 at a time.

how easy is it to pull in the clutch lever?
how easy is it to pull the clutch arm up?

Back to top

Versey's Place
Tech Section Index

IP Logged