SuzukiSavage.com - Bike won't turn over and clutch does not work.

Kirurgi YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 24	Re: Bike won't turn over and clutch does not work. Reply #15 - 08/18/22 at 03:35:28 Here is full pack as i opened it.
Back to top	20220818_130514.jpg IP Logged

Kirurgi YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 24	Re: Bike won't turn over and clutch does not work. Reply #16 - 08/18/22 at 10:09:21 Flat washer then wave washer outer part is elevated from flat. Then fat and different friction from others. Then 1 by 1 Steel and friction.
Back to top	20220818_192619.jpg IP Logged

DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4408 Honolulu	Re: Bike won't turn over and clutch does not work. Reply #17 - 08/18/22 at 23:35:08 Kirurgi, you have BIG problems with the assembly. Your Hub (4) is situated way too far inboard. It should be flush with the edges of the tangs on the basket. See area circled in green. Also, you appear to be missing two steel plates. See are circled in yellow.
Back to top	Kirurgis_Missing_Steels_Markup.jpg Knowledge is power. IP Logged

DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4408 Honolulu	Re: Bike won't turn over and clutch does not work. Reply #18 - 08/18/22 at 23:36:20 This shows the normal orientation of the hub. See how it's flush with the edge of the basket tangs.
Back to top	Clutch_Hub_Normal_Markup.jpg Knowledge is power. IP Logged

DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4408 Honolulu	Re: Bike won't turn over and clutch does not work. Reply #19 - 08/18/22 at 23:40:47 I'm thinkin the only way that hub could be so far inboard is you are missing either the inner washer (2) or the outer washer (7). This shows the inner washer. Did you install the inner washer (2)? It goes right up against the input bearing inner race. Then the spacer (3) goes on the input shaft.
Back to top	Washer__Spacer.jpg Knowledge is power. IP Logged

DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4408 Honolulu	Re: Bike won't turn over and clutch does not work. Reply #20 - 08/18/22 at 23:42:26 Then the basket goes over the spacer, and the outer washer (7) gets installed. This shows the outer washer in place against the basket.
Back to top	Washer.jpg Knowledge is power. IP Logged

DragBikeMike

Serious Thumper

Offline

SuzukiSavage.com
Rocks!

Posts: 4408
Honolulu

Re: Bike won't turn over and clutch does not work.
Reply #21 - 08/18/22 at 23:51:53

The two washers, (2) & (7), along with the spacer (3) determine the position of the hub. Your hub is too far inboard so I'm gonna guess you are missing one or both of the washers.

Regarding the missing steel plates, you should have five steel driven plates (12) and six fiber drive plates (8 & 9). One fiber plate is different. It has a larger bore to accommodate the wave washer assembly.

This shows the correct stack. On the far left is the aluminum pressure disk (13), then a fiber plate (8), then a steel plate (12), then a fiber (8), then a steel (12), then a fiber (8), then a steel (12), then a fiber (8), then a steel (12), then a fiber (8), then a steel (12), then the special fiber (9), then the aluminum hub flange.

Back to top

Plate_Stack.jpg

Knowledge is power.

IP Logged

DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4408 Honolulu	Re: Bike won't turn over and clutch does not work. Reply #22 - 08/18/22 at 23:54:16 The wave washer (11) is nested within the outermost fiber plate (9) as shown here.
Back to top	Wave_Washer__assy_1.JPG Knowledge is power. IP Logged

DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4408 Honolulu	Re: Bike won't turn over and clutch does not work. Reply #23 - 08/18/22 at 23:55:18 And the wave washer seat (10) goes on top of the wave washer. The wave washer seat is flat, the wave washer is beveled.
Back to top	Wave_Washer_Seat.JPG Knowledge is power. IP Logged

DragBikeMike

Serious Thumper

Offline

SuzukiSavage.com
Rocks!

Posts: 4408
Honolulu

Re: Bike won't turn over and clutch does not work.
Reply #24 - 08/18/22 at 23:58:20

This sketch shows how the wave washer assembly is stacked up. It's important that the flat seat (10) goes between the hub flange and the wave washer. It prevents the edge of the hard steel wave washer from digging into the soft aluminum flange.

The sketch doesn't show the fiber friction plate that surrounds the wave washer assembly.

Back to top

Wave_Washer_Installation_001.jpg

Knowledge is power.

IP Logged

DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4408 Honolulu	Re: Bike won't turn over and clutch does not work. Reply #25 - 08/19/22 at 00:01:32 Why is there no oil on any of your components? Everything under your clutch cover is bone dry.
Back to top	Knowledge is power. IP Logged

Kirurgi YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 24	Re: Bike won't turn over and clutch does not work. Reply #26 - 08/19/22 at 02:05:08 Thank you for helping. All the Steel plates are there but they are not seen in that pic. I will open whole pack today. Washers are there but I will do it again with help of these pics.
Back to top	IP Logged

Kirurgi YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 24	Re: Bike won't turn over and clutch does not work. Reply #27 - 08/19/22 at 02:09:40 Bike has been under chopping for two years. Had No time to continue this project until now. :'( plates etc have been soaked in oil and oil have been in but bike have not moves in two years. Maybe soon with your help. Thanks.
Back to top	IP Logged

Kirurgi

YaBB Newbies

Offline

SuzukiSavage.com
Rocks!

Posts: 24

Re: Bike won't turn over and clutch does not work.
Reply #28 - 08/20/22 at 14:57:50

It seems like the washer (7) has dropped off from its place when I installed the pack last time. All the others were installed probelly. Now it looks right. Snapped second pressure plate bolt when torqued 11nm. Ffs. Grin

bike is -99 and bolts can't handle torque anymore so need to replace them also. Thanks for the help.
Ps. Still No spark. Need to reinstall wiring again. Can't find fault and gonna remove all safety switches to findout if they are the problem.

Back to top

20220820_234023.jpg

IP Logged

DragBikeMike

Serious Thumper

Offline

SuzukiSavage.com
Rocks!

Posts: 4408
Honolulu

Re: Bike won't turn over and clutch does not work.
Reply #29 - 08/20/22 at 18:00:09

Your hub still looks out-of-position, too far inboard. It should be flush. Verify that the washers are the correct thickness. They should be .078" (about 2mm). The washer with a 44mm OD goes against the input shaft ball bearing. The washer with a 40mm OD goes between the basket and hub.

Can you post a picture of the back side of your hub, and one of the thrust face & bushing in the basket?

Back to top

Knowledge is power.

IP Logged