In the 5-speed savage motor does the clutch pin wear down? I know the plates go after a while, but way about the pin? I ask because the clutch arm is above the top indexing mark on the case upon clutch engagement. The clutch doesn't slip, but can I do damage being that the arm is out of the indexing marks?

Where the lever arm is in relation to the index marks when you pull the clutch lever is meaningless.  The index marks are to measure the point where the arm is located when the pin first comes in contact with the arm and clutch pack (free play removed).

If the pin gets any wear - it is minimal as the clutch release mechanism has a ball bearing where the pin makes contact.

Some clunk is normal when you are going from neutral to 1st.  If the noise is excessive....just be sure you have the cable adjusted properly with only a small amount of free play.

Wouldn't the real fix just to replace plates and springs? Like a full rebuild?

True, true...I should listen to the smart ones more often.

What I prefer is to grind full radii on both ends of the rod.
On the cam side this prevents a scrapping motion wearing the cam.
On the clutch side I've seen burrs on the rod.
It does make the rod shorter.

I also measure how much the rod sticks out.
For me 12 to 12.5 mm is purfect.

Redryder652 wrote on 08/29/16 at 18:12:00:



What will happen is that rod will pin the throwout up against the side cover and keep pressure on the clutch, allowing it to slip.
Nobody who is even decent with a clutch can wear it out in 15,000 miles. Someone who slips it excessively could rub one down pretty bad in a few months. Especially if they gas it pretty good and slowly release the clutch.