SuzukiSavage.com - clutch malfunction

MMRanch Serious Thumper Offline Evil flourishes if Good Men do Nothing. Posts: 5730 LYNCHBURG TN Gender:	clutch malfunction 12/08/20 at 19:50:40 Last time I was out on the Savage there was a malfunction ! Don't know why but ... I grabbed the clutch and and was greeted with a crack from the right crank-case , followed by a non-disengaging clutch. ....................................... Here is a picture of the broken piece .
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MMRanch Serious Thumper Offline Evil flourishes if Good Men do Nothing. Posts: 5730 LYNCHBURG TN Gender:	Re: clutch malfunction Reply #1 - 12/08/20 at 20:00:46 From what I could tell , the part wasn't in so many pieces when it left its perch. So , it bounced around between the spinning Clutch and the side plate a while . Notice : One of those gouges is really deep !
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MMRanch Serious Thumper Offline Evil flourishes if Good Men do Nothing. Posts: 5730 LYNCHBURG TN Gender:	Re: clutch malfunction Reply #2 - 12/08/20 at 20:01:57 The side cover
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MMRanch Serious Thumper Offline Evil flourishes if Good Men do Nothing. Posts: 5730 LYNCHBURG TN Gender:	Re: clutch malfunction Reply #3 - 12/08/20 at 20:05:29 The worse part !
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: clutch malfunction Reply #4 - 12/08/20 at 20:35:52 If I had the skills I'd turn a billet throwout. Sintered metal breaks And the design is crap. That's a hard inside ninety, and that invites cracking. My opinion,
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MMRanch

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Re: clutch malfunction
Reply #5 - 12/08/20 at 20:47:28

Yea , my thought exactly !

The sides are flat where the shaft goes through so ... making one is not an option.

But

What is an option is : The factory clutch springs are 2.9mm wire , 7 coils
The springs from the "clutch kit" are 2.2mm wire 9 coils.

I'm going with the 2.2mm this time. Not sure about using all 9 coils either ? This is the second one of these I've broken. ??? Undecided

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28763 L.A. California Gender:	Re: clutch malfunction Reply #6 - 12/08/20 at 22:11:18 More coils are softer. thinner wire is softer.
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MMRanch

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Re: clutch malfunction
Reply #7 - 12/09/20 at 08:23:21

So Versey , I've been thinking :

2.9mm * 7 coils = 20.3mm of spring

2.2mm * 9 coils = 19.8mm of spring

2.2mm * 8 coils = 17.6mm of spring ,

When my clutch started slipping before , I found the fiber plates were NOT worn enough to matter.

The metal plates were not worn either.

What I found was the back-side of the clutch pack had worn (aluminum). It was so worn that the inside of the pack could not close on the plates to pinch them together. No matter how much spring is/was pushing the pack together.

So , I just added an extra metal plate to the pack and it 100% fixed the slipping.
...........................

So now I'm wondering : In the interest of making things as easy as possible on the clutch rod pushing device . Do we really need all 9 of those coils ?

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LANCER Serious Thumper Alliance Member Offline Savage Beast Performance Parts Posts: 10604 Oklahoma Gender:	Re: clutch malfunction Reply #8 - 12/09/20 at 10:59:22 Yep, it broke. Mike, why are you breaking what was a perfectly good bike ? 😏
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verslagen1

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Re: clutch malfunction
Reply #9 - 12/09/20 at 11:25:25

MMRanch wrote on 12/09/20 at 08:23:21:

So Versey , I've been thinking :

2.9mm * 7 coils = 20.3mm of spring

2.2mm * 9 coils = 19.8mm of spring

2.2mm * 8 coils = 17.6mm of spring ,

...........................

So now I'm wondering : In the interest of making things as easy as possible on the clutch rod pushing device . Do we really need all 9 of those coils ?

OK, so 9 coils is a longer spring than 7 coils.
if you take a 9' bar put it in a vice along with a 7' bar and hang a 1 pound wt. on the end of each bar you'll see the 9' bar hangs lower.

now you take a 9 coil spring with x diameter wire and put 1 pound of wt on it will hang lower than a 7 coil spring with y diameter wire if they start at the same length.

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MMRanch

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Re: clutch malfunction
Reply #10 - 12/09/20 at 17:19:30

the smaller 9 coil spring is taller w/no load

I don't know why it broke ? but its the second time it's happened to me on this bike ... I wonder if it just me grabbing it to quick ?
I'll be getting some "drill-rod" to custom make a new pushing rod this time , just to make sure its operating as close to the 90 deg. engagement angle as possible.

I thought I was getting "weaker" in my RETIREMENT YEARS ?

Either way ,,, If ya want a different result ... ya got to do something different ! I ordered parts last night and I'm going with the 2.2mm wire w/8 coils instead of the 9 coils. The 2.9mm coils just ain't working for me , I could have been in the middle of Texas when that thing broke instead of <10 miles from home .

The worse result would be a slippy clutch and a need to revisit the springs with a trip to the spring isle at tractor supply .
On the other hand , It could be a easy-pull and never break again ! Grin

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28763 L.A. California Gender:	Re: clutch malfunction Reply #11 - 12/09/20 at 21:32:03 MMRanch wrote on 12/09/20 at 17:19:30: the smaller 9 coil spring is taller w/no load You have to be careful not to bottom out the spring (fully collapse) That raises the stress on everything a lot.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: clutch malfunction Reply #12 - 12/09/20 at 21:43:53 Put a new o ring in the cover where the rod passes through
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Hiko Senior Member Offline SuzukiSavage.com Rocks! Posts: 250 Tauranga New Zealand Gender:	Re: clutch malfunction Reply #13 - 12/09/20 at 23:16:22 I Agree with Versy If the spring becomes coil bound {fully compressed} that would put a big load on the operating mechanism and possibly be the cause of your woes. Is this possible due to modifications to the clutch pack?
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norm92de Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1180 El Paso TX Gender:	Re: clutch malfunction Reply #14 - 12/10/20 at 08:35:21 I agree with Versy bottoming out the springs is VERY bad. Not sure how you achieved that if your cable is adjusted properly? The clutch lever must have been very hard to pull in!
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