SuzukiSavage.com - Jerks and stalls when I drop into first gear :/

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Jerks and stalls when I drop into first gear :/
08/01/18 at 15:55:18

just bought this 01’ Savage. I’ve stripped the ugly plasti dip job and got that nice stock paint back out. Replaced push rod actuator inside the valve cover that pushes the rod when the clutch is pulled in.
Got some valvoline oil from Walmart and read a couple posts here saying that you have to have the right oil for your bike in order to work properly So I bought some Suzuki oil at SoCal moto in Brea Orange County.

It runs nice and smooth but I pull the clutch in drop to first and it jerks and stalls or just dies

Clutch cable ? Push rod ? Oil ? Neutral or clutch safety switch bad ???
HELPP. PLZ

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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: Jerks and stalls when I drop into first gear : Reply #1 - 08/01/18 at 18:59:18 You can't put the bike in gear if the side stand is down, there is a button switch(safety) on the stand that grounds the ignition and kills the motor. neutral is just a light, if the clutch switch was bad the starter wouldn't run.
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JAGGUY YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 27 Riverside Ca.	Re: Jerks and stalls when I drop into first gear : Reply #2 - 08/01/18 at 19:36:49 If it was the side stand switch the engine would die without jerking. If the engine is stalling with a jerk by going into gear then it seems a clutch adjustment is in order. With the key off can you put it in gear, pull in the clutch and roll the bike around?
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OCMike_LS650 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 19	Re: Jerks and stalls when I drop into first gear : Reply #3 - 08/01/18 at 21:00:22 Sidestand is up . Bike is in Neutral. I hold in the clutch. As soon as I put it into first it jerks and dies
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Jerks and stalls when I drop into first gear : Reply #4 - 08/02/18 at 00:29:49 How much slack in the clutch cable?
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Dave

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Re: Jerks and stalls when I drop into first gear :
Reply #5 - 08/02/18 at 05:08:25

OCMike_LS650 wrote on 08/01/18 at 21:00:22:

Sidestand is up . Bike is in Neutral.

If the sidestand switch is faulty......the switch assumes the sidestand is down regardless of where it really is.

When the sidestand is down....the switch is in the open position and will not allow current to pass through. When the sidestand is up the switch is closed and a signal can go through to the running circuit and the bike stays running when the neutral light goes out (put the bike in gear). So...you need to use a meter and test the switch to see if it is good and goes from open/closed when you move the kickstand. As an alternative you can bypass the switch and see if that changes anything - take the connector that is on the left side frame just above the sprocket cover, and jumper the connector on the uphill side to complete the circuit. If the bike stays running when you put it in gear....that proves your sidestand switch is not working.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Jerks and stalls when I drop into first gear : Reply #6 - 08/02/18 at 07:38:05 Can you roll it in gear? It Jerks Is the clutch adjusted?
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batman

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Re: Jerks and stalls when I drop into first gear :
Reply #7 - 08/02/18 at 20:58:52

When you have a problem it's usually the last place you've been. If the bike jerks it's because the clutch may be still fully engaged. You replaced the throughout piece on the clutch that should engage the end of the rod, but if you didn't lift the outside clutch arm to about a 90 degree angle when replacing the side cover the rod could be on top side of the piece, and when you squeeze the clutch lever your taking slack out of the cable but not really disengaging the clutch. look at the side case ,there is two lines (about 1/2 inch apart) etched on the case the end of the arm where the cable is ,the arm should fall somewhere between those lines.

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OCMike_LS650

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Re: Jerks and stalls when I drop into first gear :
Reply #8 - 08/02/18 at 21:11:12

Batman I think u earned yourself a six pack. I read that part somewhere on here in a post before but I couldn’t find it again. I will try it tomorrow let’s see how it goes. If I put the arm lever in between the two marks the clutch lever does not engage or disengage one bit. It goes up but doesn’t push the rod in.

When I can feel the rod push the plates in the lever is sitting way higher then it should be.
This is my sixth time opening up the clutch cover. Seven times a charm ?
Thanks to everybody for the help

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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: Jerks and stalls when I drop into first gear : Reply #9 - 08/02/18 at 21:40:17 Well sometimes it takes me a while ,but you "jerked" my brain
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OCMike_LS650 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 19	Re: Jerks and stalls when I drop into first gear : Reply #10 - 08/02/18 at 21:59:39 😅😅😅😅 Haha How can I post pictures on here says file is too big
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Re: Jerks and stalls when I drop into first gear :
Reply #11 - 08/03/18 at 06:53:27

OCMike_LS650 wrote on 08/02/18 at 21:59:39:

😅😅😅😅
Haha
How can I post pictures on here says file is too big

Images can't be larger (file size) than 2mb. If they are, use something like 'paint' to resize them. For example, if the image is physically 3000 x 3000 pixels, resize it to 1000 x 1000 pixels in physical size and that will reduce the 'file size' when re-saved.

Hope that helps.

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OCMike_LS650 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 19	Re: Jerks and stalls when I drop into first gear : Reply #12 - 08/03/18 at 12:14:49 Here’s a pic of the build at the moment.
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