SuzukiSavage.com - Lost my clutch lever today

transam4life

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Re: Lost my clutch lever today
Reply #15 - 05/26/24 at 07:47:38

DragBikeMike wrote on 05/25/24 at 22:51:45:

Transam, do a good visual inspection for cracks in your clutch cover. I can see from your picture indications that look an awful lot like cracks. The remnants of the cam may have gotten wedged between the rotating clutch and the cover. This markup shows what I am concerned about.

Thank you for showing me that picture. I actually noticed that last night and wondered if that was a crack as well. I plan on taking a 2nd look later today. If that is indeed a small crack the only repair is by buying a new clutch cover correct?

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transam4life

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Re: Lost my clutch lever today
Reply #16 - 05/26/24 at 07:52:53

DragBikeMike wrote on 05/25/24 at 23:03:53:

"As far installation on the diagram above...Do I just buy a new pin #28 and slide the shaft out and then install the new cam #23?"

That's pretty much all there is to changing the cam, but pay attention to Micheal Moore's comment about deburring the shaft before you try to pull it out of the clutch cover. Burrs develop on the shaft as it gets worn by the cam. The burrs tear up the bore in the cover when you remove the shaft. If you go to pull out the shaft, and if it's tight or feels like it's binding, STOP. Push it back in and clean up the burrs.

This YouTube vid will give you more than enough detail on replacing the cam.

https://www.youtube.com/watch?v=ccZbhM9J5PA

Awesome, that explains everything! I will def be deburring as well if needed.

Am I suppose to buy a new shaft as well when replacing the cam? The video shows quite a bit of play from a used shaft and new cam. He talks about a shim, but not sure where I would get one of those from...

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Graybeard YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 41	Re: Lost my clutch lever today Reply #17 - 05/26/24 at 08:06:07 Get a cam. See how it fits the shaft.
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Michael Moore Junior Member Offline SuzukiSavage.com Rocks! Posts: 85 In the fog of San Francisco	Re: Lost my clutch lever today Reply #18 - 05/26/24 at 09:02:40 transam4life wrote on 05/26/24 at 07:52:53: He talks about a shim, but not sure where I would get one of those from... DBM made the shim from a feeler gauge of an appropriate thickness.
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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1282 Houston, Texas Gender:	Re: Lost my clutch lever today Reply #19 - 05/26/24 at 10:06:34 And the guru in the video is DragBikeMike himself! Sadly, The Sneeze lost his shop in a fire and his custom-made hardened clutch cam production isn’t a priority for him right now.
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transam4life Junior Member Offline SuzukiSavage.com Rocks! Posts: 99	Re: Lost my clutch lever today Reply #20 - 05/26/24 at 11:08:10 Graybeard wrote on 05/26/24 at 08:06:07: Get a cam. See how it fits the shaft. Yeah I already have the cam on order, the shaft was $90 so I held off on that assuming I could reuse, but if I have to buy a new one I will. How much play should there be on the cam?
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transam4life Junior Member Offline SuzukiSavage.com Rocks! Posts: 99	Re: Lost my clutch lever today Reply #21 - 05/26/24 at 11:08:49 Michael Moore wrote on 05/26/24 at 09:02:40: transam4life wrote on 05/26/24 at 07:52:53: He talks about a shim, but not sure where I would get one of those from... DBM made the shim from a feeler gauge of an appropriate thickness. How much play is normal?
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transam4life Junior Member Offline SuzukiSavage.com Rocks! Posts: 99	Re: Lost my clutch lever today Reply #22 - 05/26/24 at 11:11:53 https://ibb.co/3pzDQJx https://ibb.co/dKLmGhH https://ibb.co/XJTQ9Pw https://ibb.co/ZxRpRd2 https://ibb.co/7bMSfBh I took some additional photos of the inside of the case. To the best of my knowledge it doesn't seem cracked...just casting marks. I found other spots inside the case that look similar. What do you guys think?
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Michael Moore Junior Member Offline SuzukiSavage.com Rocks! Posts: 85 In the fog of San Francisco	Re: Lost my clutch lever today Reply #23 - 05/26/24 at 13:41:28 You might want to get a dye penetrant crack testing kit or supplies to be sure: https://grassrootsmotorsports.com/articles/testing-cracks-home-diy-dye-penetrant s/ but the materials aren't inexpensive https://www.amazon.com/Dye-Penetrant-Crack-Finder-Kit/dp/B00XLW4BRC/ref=sr_1_3
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transam4life

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Re: Lost my clutch lever today
Reply #24 - 05/26/24 at 13:55:45

Michael Moore wrote on 05/26/24 at 13:41:28:

You might want to get a dye penetrant crack testing kit or supplies to be sure:

https://grassrootsmotorsports.com/articles/testing-cracks-home-diy-dye-penetrant
s/

but the materials aren't inexpensive

https://www.amazon.com/Dye-Penetrant-Crack-Finder-Kit/dp/B00XLW4BRC/ref=sr_1_3

That's pretty neat...I didn't know they made such a kit. I think a new clutch cover is $225 brand new or much less used on Ebay so I'm not sure investing $75 would be worth it for the kit. Maybe I can take it to a machine/race shop and see if they can check the crack for me for a smaller fee.

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Michael Moore Junior Member Offline SuzukiSavage.com Rocks! Posts: 85 In the fog of San Francisco	Re: Lost my clutch lever today Reply #25 - 05/26/24 at 16:48:57 A place that maintains airplanes or big diesels is another possibility for having crack detection stuff on hand. "magnaflux" only works on ferrous materials so non-ferrous like aluminum gets dye penetrant tested or x-rayed.
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DragBikeMike

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Re: Lost my clutch lever today
Reply #26 - 05/26/24 at 18:37:18

"Thank you for showing me that picture. I actually noticed that last night and wondered if that was a crack as well. I plan on taking a 2nd look later today. If that is indeed a small crack the only repair is by buying a new clutch cover correct?"

I got to thinkin about this supposed crack and how it could be just casting flash, so I disassembled my spare cover and took a look see. Whadyaknow, same thing.

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Before_Polish_My_Spare_Cvr.jpg

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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4284 Honolulu	Re: Lost my clutch lever today Reply #27 - 05/26/24 at 18:40:06 Examination at 5X indicated casting flash. To make sure, I polished it with 220 grit wet & dry abrasive. All gone in just s few minutes. I think your cover is just fine. Polish the blemish with 220 grit and verify that it disappears. Then forge ahead. Sorry for any confusion. Always better safe than sorry.
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transam4life Junior Member Offline SuzukiSavage.com Rocks! Posts: 99	Re: Lost my clutch lever today Reply #28 - 05/26/24 at 18:44:51 Thanks to DragBikeMike and Michael Moore for the help with the clutch cover "crack". After seeing your photos I think it is casting flash as well. Would sanding down the part effect the cam positioning at all? I know it sits on that "slopped ledge"...
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4284 Honolulu	Re: Lost my clutch lever today Reply #29 - 05/26/24 at 19:59:04 Sanding that hard-stop won't hurt anything. You only want to remove the visual indication. If it turns out to be an actual crack, you will wear your finger out before you hurt the hard-stop.
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