SuzukiSavage.com - clutch push rod

rbeathe YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 19	clutch push rod 02/26/19 at 16:44:37 My clutch pushrod fell out while I had the right side crankcase cover off. Now I can't get the clutch lever cam to push the pushrod in to engage the clutch. Im I just missing something fundamental here?
Back to top	IP Logged

justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: clutch push rod Reply #1 - 02/26/19 at 17:17:37 So, you cleaned up and reinstalled the rod. Did you then stick the side cover back on with a few bolts and test? Which way is the clutch arm pointed?
Back to top	The people never give up their liberties but under some delusion.- Edmund Burke. IP Logged

batman

Serious Thumper

Offline

SuzukiSavage.com
Rocks!

Posts: 3806
osceola new york
Gender: male

Re: clutch push rod
Reply #2 - 02/26/19 at 19:27:48

You have to lift up on the clutch arm (to about level) when putting the side case on . When you have the case on but before bolting , raise the clutch arm a little ,if the case starts being pushed off towards you ,release the clutch arm slowly while pushing the case back in and bolt it up ,you're good, you've centered the rod in the recess of the release cam.
the problem you have now stems from the rod being jammed between the top of release cam and the inside top of the side cover. The rod can't be pushed in and the clutch lever(be gentle they break) can't move up.

Back to top

« Last Edit: 02/27/19 at 17:23:40 by batman »

my old work mates called me MacGyver

IP Logged

rbeathe YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 19	Re: clutch push rod Reply #3 - 02/27/19 at 07:24:52 Should you be able to engage the pushrod with thumb pressure?
Back to top	IP Logged

verslagen1

YaBB Moderator
ModSquad

Offline

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

Posts: 28782
L.A. California
Gender: male

Re: clutch push rod
Reply #4 - 02/27/19 at 07:39:05

rbeathe wrote on 02/27/19 at 07:24:52:

Should you be able to engage the pushrod with thumb pressure?

You're pushing against 6 springs that you can't compress individually with your hand.
Huh

no, you're not going to be able to push in the rod with your thumb.

If you took your clutch apart and now it doesn't operate, you didn't put it back together correctly.

Back to top

Versey's Place
Tech Section Index

IP Logged

rbeathe YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 19	Re: clutch push rod Reply #5 - 02/27/19 at 10:32:19 ...didn't think so, thanks. I bet its just the lever position like Batman says!
Back to top	IP Logged

justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: clutch push rod Reply #6 - 02/27/19 at 17:18:51 Five inch lever with a cable that lifts a lever that pushes the throwout . No. You can not hope to push it with your thumb, hammer handle, nothing..
Back to top	The people never give up their liberties but under some delusion.- Edmund Burke. IP Logged

batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: clutch push rod Reply #7 - 02/27/19 at 17:30:51 That's why the case will move back toward you because you can't depress the valve springs. the fact that it moves back tells you the rod is engaged in the cam, if not lifting the arm ( if it even moves) wouldn't do anything (like the condition you have it now).
Back to top	« Last Edit: 03/03/19 at 15:05:04 by batman » my old work mates called me MacGyver IP Logged

justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: clutch push rod Reply #8 - 02/27/19 at 21:05:05 I hope he can get the gist of it with us joining in. Hopefully he didn't break the throwout. If you didn't change the oring on the shaft through the case, I would do that..
Back to top	The people never give up their liberties but under some delusion.- Edmund Burke. IP Logged

eau de sauvage Serious Thumper Offline Posts: 2565 Queensland Gender:	Re: clutch push rod Reply #9 - 02/28/19 at 01:34:33 while we're all here, I have a feeling that the next time I have the clutch cover off that I'm going to snap of the tang that you have to bend up to get the clutch cable out. So my question is, when that tang snaps off what is the best workaround.
Back to top	MAGA! Make the Assholes Go Away IP Logged

Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17832 Camp Springs, Kentucky Gender:	Re: clutch push rod Reply #10 - 02/28/19 at 03:30:09 eau de sauvage wrote on 02/28/19 at 01:34:33: So my question is, when that tang snaps off what is the best workaround. I have wondered that myself - seems like 5 or 6 times and the tang will likely snap (your mileage may vary). Safety wire, zip tie.....drill a hole and put in a cotter pin.
Back to top	Someday I will be old......But not today! IP Logged

justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: clutch push rod Reply #11 - 02/28/19 at 06:39:05 I don't know that the cable can get outta there even if the thing snaps off. Make sure you rotate the cable holder into position before you bolt the side cover on. And Both nuts go on Top of the cast aluminum pedestal for the clutch cable housing landing. Or, you'll break it.
Back to top	The people never give up their liberties but under some delusion.- Edmund Burke. IP Logged

verslagen1

YaBB Moderator
ModSquad

Offline

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

Posts: 28782
L.A. California
Gender: male

Re: clutch push rod
Reply #12 - 02/28/19 at 06:42:18

eau de sauvage wrote on 02/28/19 at 01:34:33:

while we're all here, I have a feeling that the next time I have the clutch cover off that I'm going to snap of the tang that you have to bend up to get the clutch cable out.

So my question is, when that tang snaps off what is the best workaround.

If I remember correctly, there's a hole for a little cotter pin.
Or don't worry about it, I haven't ever pushed the tab back in.

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 push rod Reply #13 - 02/28/19 at 07:54:49 I just leave it alone. Most bikes using a similar system don't use a tab.
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 push rod Reply #14 - 02/28/19 at 15:53:53 Norm is correct ,it's unneeded , the cable end fits up into the hole in the "stirrup" ,the cable when adjusted doesn't have enough slack in it to allow the cable to jump/slip/fall ? out.
Back to top	my old work mates called me MacGyver IP Logged