SuzukiSavage.com - Clutch Cable / Arm

Mekh

Full Member

Offline

Suzuki Savage Rocks!

Posts: 128
Denmark
Gender: male

Clutch Cable / Arm
04/09/17 at 06:11:46

Hi,

I'm about to install new clutch cable and noticed that the lever arm is located really high relative to the markings on the engine.

I have cleaned the clutch plates, so assume that is why, but... What do I need to do to fix this issue?

A longer/shorter actuator pin? (or whatever it is rightfully called... The pin which the lever arm push into the clutch plate assembly)

https://www.dropbox.com/s/0nu9isamndiidq7/2017-04-09%2014.49.55%20-%20Kopi.jp...
PS. I have inserted a picture, but the preview will not show it for some reason...

Back to top

IP Logged

verslagen1

YaBB Moderator
ModSquad

Offline

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

Posts: 28761
L.A. California
Gender: male

Re: Clutch Cable / Arm
Reply #1 - 04/09/17 at 09:28:10

You need a longer pin, it may work, but what you end up with is not being able to get enough throw to get the clutch completely disengaged.

they're cheap, order all 3 unless you which one you do have and I would order a couple extra long ones. I'll tell you why, I like to maximize the rod length sticking out of the clutch pack to 12 to 12.5mm, it'll give you the max clutch operation. I also grind a full radius on both ends to minimize friction.

But somewhere between 12.5 and 13mm is too long and when you torque down the cover it actuates the clutch and you don't go anywhere.

Back to top

Versey's Place
Tech Section Index

IP Logged

Mekh Full Member Offline Suzuki Savage Rocks! Posts: 128 Denmark Gender:	Re: Clutch Cable / Arm Reply #2 - 04/09/17 at 10:26:48 Thank you. I can see four part no's for that part. Do you happen to know the default length and what lengths the other pins are?
Back to top	IP Logged

verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28761 L.A. California Gender:	Re: Clutch Cable / Arm Reply #3 - 04/09/17 at 11:47:37 no
Back to top	Versey's Place Tech Section Index IP Logged

norm92de Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1180 El Paso TX Gender:	Re: Clutch Cable / Arm Reply #4 - 04/09/17 at 14:28:34 Why is the clutch arm higher on the case? if the clutch is worn, even somewhat, the arm will be lower on the case. I would say that something else is amiss.
Back to top	2014 S40. Raptor. idle mixture adj.Needle raised one notch. 4000' altitude. Stock jets. Shell Rotella synthetic. IP Logged

verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28761 L.A. California Gender:	Re: Clutch Cable / Arm Reply #5 - 04/09/17 at 14:59:08 I've assumed that you just took up the slack in the cable and not disengaged the clutch? disk wear, arm goes down rod wear, arm goes up
Back to top	Versey's Place Tech Section Index IP Logged

norm92de Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1180 El Paso TX Gender:	Re: Clutch Cable / Arm Reply #6 - 04/10/17 at 10:10:59 That brings up a question. Which wears out most the rod or the clutch plates? I guess it depends on how the clutch is used/abused. Probably sitting at lights in gear is also a factor.
Back to top	2014 S40. Raptor. idle mixture adj.Needle raised one notch. 4000' altitude. Stock jets. Shell Rotella synthetic. IP Logged

batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: Clutch Cable / Arm Reply #7 - 04/10/17 at 12:45:19 The rod,when you squeeze in the clutch the plates disengage ,there is no wear.There has only been ONE report of someone actually having worn the clutch plates to the point of replacement.
Back to top	my old work mates called me MacGyver IP Logged

youzguyz

Serious Thumper

Offline

Posts: 2524
San Antonio, Texas
Gender: male

Re: Clutch Cable / Arm
Reply #8 - 04/10/17 at 13:11:47

Mekh wrote on 04/09/17 at 10:26:48:

Thank you. I can see four part no's for that part. Do you happen to know the default length and what lengths the other pins are?

Ron Ayers says:

http://www.ronayers.com/oemparts/a/suz/50d32fb6f8700232d0b3d922/clutch

22-1ROD, CLUTCH PUSH (L:44.5MM) p/n 23111-24B00-445

22-2ROD, CLUTCH PUSH (L:45.5MM) p/n 23111-24B00-455

22-3ROD, CLUTCH PUSH (L:46.5MM) p/n 23111-24B00-465

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

youzguyz

Serious Thumper

Offline

Posts: 2524
San Antonio, Texas
Gender: male

Re: Clutch Cable / Arm
Reply #9 - 04/10/17 at 13:16:29

batman wrote on 04/10/17 at 12:45:19:

The rod,when you squeeze in the clutch the plates disengage ,there is no wear.There has only been ONE report of someone actually having worn the clutch plates to the point of replacement.

You MIGHT be talking about me.

I wore my clutch out, and I got a gently used one from Lancer.

Now I THINK, I used the push rod he sent me, but I can't be sure.
I KNOW that the arm was right where it was suppose to be when I put it all together.
So, if I replaced the rod, then the original is setting here on my desk right now, and it is 45.5 mm long. No wear.

Now, when I stop at a light or something, I normally put the bike in neutral and release the clutch.

If someone else is in the habit of keeping the bike in gear and the clutch lever pulled in, they would likely see more wear on the rod.

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

norm92de Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1180 El Paso TX Gender:	Re: Clutch Cable / Arm Reply #10 - 04/10/17 at 14:32:38 I leave my bike in gear at a light because it clunks horribly when I put it in gear after stopping. I can't stand the clunk. :'(
Back to top	2014 S40. Raptor. idle mixture adj.Needle raised one notch. 4000' altitude. Stock jets. Shell Rotella synthetic. IP Logged

batman

Serious Thumper

Offline

SuzukiSavage.com
Rocks!

Posts: 3806
osceola new york
Gender: male

Re: Clutch Cable / Arm
Reply #11 - 04/10/17 at 15:00:14

I leave my bike in gear because I think being in neutral is dangerous! I don't want to be fiddling around trying to get my bike in gear if a car behind me doesn't appear to stopping in time and is about to drive me into the car ahead or into the intersection 's cross traffic I want to be able to move NOW! .I'll gladly pay the price of a new clutch push rod ,rather than die.

Back to top

my old work mates called me MacGyver

IP Logged

norm92de Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1180 El Paso TX Gender:	Re: Clutch Cable / Arm Reply #12 - 04/10/17 at 15:13:33 I didn't think that applied to you Caped Crusader, you can just fly over the intersection and leave the bike to the traffic.
Back to top	2014 S40. Raptor. idle mixture adj.Needle raised one notch. 4000' altitude. Stock jets. Shell Rotella synthetic. IP Logged

justin_o_guy2

Serious Thumper

Offline

What happened?

Posts: 55279
East Texas, 1/2 dallas/la.

Re: Clutch Cable / Arm
Reply #13 - 04/10/17 at 16:40:41

[quote author=43554F405D4F43403A0 link=1491743506/0#8 date=1491855107]Mekh wrote on 04/09/17 at 10:26:48:

Thank you. I can see four part no's for that part. Do you happen to know the default length and what lengths the other pins are?

Ron Ayers says:

http://www.ronayers.com/oemparts/a/suz/50d32fb6f8700232d0b3d922/clutch

22-1ROD, CLUTCH PUSH (L:44.5MM) p/n 23111-24B00-445

22-2ROD, CLUTCH PUSH (L:45.5MM) p/n 23111-24B00-455

22-3ROD, CLUTCH PUSH (L:46.5MM)

Which one is the stock length?

Back to top

The people never give up their liberties but under some delusion.- Edmund Burke.

IP Logged

norm92de Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1180 El Paso TX Gender:	Re: Clutch Cable / Arm Reply #14 - 04/11/17 at 13:27:39 Justin, I don't know, but My guess is that the middle length is stock. 45.5mm.
Back to top	2014 S40. Raptor. idle mixture adj.Needle raised one notch. 4000' altitude. Stock jets. Shell Rotella synthetic. IP Logged