I'd say you need a new throw out rod, you got that adjustment maxed out.
the end of that ferrule is a little nub that the rubber bit fits on.

Thanks guys, OK I screwed the cable in till the nipple poked out enough to slip the boot over it. This meant that I had to screw the fine adjuster out at the handlebar end a fair way. So the defining limit on how close I can have that adjusting nut is defined by the minimum I can have the nipple poking out so I can slip the boot over it! No wiggle room there. So while I can't start with it screwed all the way in as Suzuki say, it has at least a good quarter inch still hanging on as per photo below.

I have another observation though that I find a little puzzling, it seems to me that the locknut on the clutch end adjuster would make more sense being below the adjuster nut rather than above it. Anyway what I find puzzling is that this particular arrangement as it currently is and I assume is factory spec leaves it fairly loose. See video, is this level of movement normal? It doesn't even sit flush against the housing. btw that the camera moving not the bike. https://youtu.be/5ZIaMVNCRL0

EDIT: @Batman, I just saw that last bit, never noticed those marks before, it is  right at the level of the top mark. Does this mean a new throw out rod is in order. If so is it a big deal to fix, and is this normal to need one this early?

Gotta say though clutch feels fine, no slipping.

EDIT 2: I loosened the clutch at the handlebar end so the lower clutch lever would be nice and loose, after pushing up with two fingers till I felt some decent resistance the bottom of the clutch lever was just barely above the upper mark! Does this sound like I need to order a longer clutch pushrod?

@Dave, OK will order them. Is it normal for the clutch to wear to the next size rod after 12,000kms? I'm guessing I'll need the next bigger size rod, yes? From what I've read so far the OEM rod will be the middle of 3?

I am also perplexed, neither I nor the gf whose bike this is, ride in a manner that's harsh on the clutch. We only relatively occasionally gun it, and I always avoid slipping the clutch.

BTW, you misunderstood about the locknut, I didn't mean that it should be on the bottom of the lever, I meant that it should be under the adjusting nut rather than on top of it. But probably wouldn't help though.

So should I get the longer sized pushrod, or a shorter one? I'm guessing longer but it's always good to check!


Dave wrote on 06/10/17 at 06:14:29:

@Batman,

Well if it's pushrod wear then I guess it's going to need a longer one. I'll grab the necessary items but seeing as the clutch is working fine at the moment would this be something that could hold off for say 4 months as I just changed the oil and I don't feel much like wrenching in the winter. With the lever at the top mark does not mean there is an urgency to this does it?