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General Category >> Rubber Side Down! >> Clutch Cable assistance
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Message started by Samhines6 on 11/25/24 at 15:04:57

Title: Clutch Cable assistance
Post by Samhines6 on 11/25/24 at 15:04:57

Hello all. Long time listener, first ish time caller.

I was doing bits and bobs in my garage when something on my person caught on the clutch cable of my Savage. I just have turned the wrong way, because I gave it a solid yank by accident and stripped the tension screw on the clutch lever. Well, I replaced that today, and now I have no tension on my clutch lever whatsoever, at any adjustment point available on the screw. Unfortunately, my Savage is a bit torn down at the moment and I can't fire it up to help diagnose.

Any ideas? Stretched clutch cable? Any help is appreciated:)

Title: Re: Clutch Cable assistance
Post by JOG on 11/25/24 at 16:44:50

Grab the lever ,the one the clutch cable lifts.
Lift it.
If you feel good resistance, the cable broke.
If not, your throwout broke.

Title: Re: Clutch Cable assistance
Post by Dave on 11/25/24 at 16:44:54

What does the cable look like down on the bottom....at the engine. Is everything still hooked up down there?

What is the chrome clutch arm on the engine case doing - is the lever between the 2 little marks on the case? (Perhaps you yanked on things hard enough to break the clutch cam inside the case).

Title: Re: Clutch Cable assistance
Post by Samhines6 on 11/25/24 at 16:58:02

Title: Re: Clutch Cable assistance
Post by Samhines6 on 11/25/24 at 17:05:44

Don't judge my scrap battery door too harshly :D

Title: Re: Clutch Cable assistance
Post by JOG on 11/25/24 at 19:25:18

Jog: the cable is definitely not broken. It can still flop around that lever. When I lift said lever, there is no tension or sprung resistance beyond that of the cable weighing down on it.

The throwout broke. Gotsta pull the side cover. Replace the twenty cent O-Ring the shaft goes through, too.
On cardboard, draw the outline of the cover. Cut a slot for each screw. As you remove them, put them in their respective slot. Saves much drama going together.

Title: Re: Clutch Cable assistance
Post by Samhines6 on 11/25/24 at 20:35:40

10-4, I'll add it to the to-do list. I appreciate the expertise.

Is this the part I'm after? [ch128071]
https://www.partzilla.com/product/suzuki/23263-24B01?

Title: Re: Clutch Cable assistance
Post by JOG on 11/25/24 at 22:02:54

That be the Thang you need.
You should be happy that happened with the engine off. When mine died it took out the cam chain guide,too.

Title: Re: Clutch Cable assistance
Post by Dave on 11/26/24 at 02:24:04

This is the photo of your bike I want to see. The lever on the side of the engine should be between the marks with light pressure holding the lever upward.

If you lever goes upward without resistance - then the clutch cam could be broken.

Title: Re: Clutch Cable assistance
Post by JOG on 11/26/24 at 04:24:38

Dave, why do you have an engine sitting on a bench?

Title: Re: Clutch Cable assistance
Post by Dave on 11/26/24 at 04:48:13

7D485B43585F5B485E3A0 wrote:

Dave, why do you have an engine sitting on a bench?

That photo was stolen from one of DragBikeMike's threads.

However - I currently have 1 newly refurbished 97mm Wiseco engine on a bench waiting to go into my Retro Standard bike, 1 low mileage spare from a 2005 on a dolly on the floor, and 1 very used engine in the Retro Standard frame while I do the welding and changes needed to make it a resemble a 60's/70's era bike.

For some reason I just have the need to keep some projects around!

Title: Re: Clutch Cable assistance
Post by Samhines6 on 11/26/24 at 06:10:04

Jog: Thank you for the confirmation and the o-ring suggestion. Is there anything else i should do/replace while I'm "in there"? I recently changed to a chain drive w/ a taller rear end; I've heard suggestions of higher pressure clutch springs to prevent slippage.

Dave: apologies, I'll grab that when I'm off today. Should I slap an adjustable wrench on like that as well? I didn't know if it acted as a tensioner to help diagnose through the pic.

Both of ya: Thank you so much for the quick assistance. Still blows my mind that there exists a forum of knowledgeable folks like you guys for a bike that's been out of production for half a decade.

:)

Title: Re: Clutch Cable assistance
Post by Dave on 11/26/24 at 07:01:04

1E2C20252423283E7B4D0 wrote:

I've heard suggestions of higher pressure clutch springs to prevent slippage.

Dave: Should I slap an adjustable wrench on like that as well?

It is not a good idea to install stronger springs - that is asking for the clutch release cam to break.....it is not very strong.

The wrench is only on there to provide a bit of lift on the lever...you could use rubber bands - or just push up with your finger. If the lever easily goes past the upper line that is a clue you have a problem inside.

Title: Re: Clutch Cable assistance
Post by ThumperPaul on 11/26/24 at 09:05:14

This seems very coincidental or “chicken or the egg” to me…replace the tension screw and the problem develops??

Are you sure your clothing snagged on it? Or did something else happen that caused it to strip out?

Either way, you’re in good hands with these guys assisting!

Title: Re: Clutch Cable assistance
Post by Samhines6 on 11/26/24 at 09:12:21

Dave: noted re: clutch springs. Thanks for shooting that down before I broke something else.

Thumper Paul: Nah, it's definitely my fault haha. I felt something(s) snap when I caught myself on the clutch cable. I was hoping that all that broke was that tensioning screw, but it's looking like I took out the clutch release cam too :o Guess that'll give me an opportunity to get comfortable with the clutch system (hurray optimism!).

Title: Re: Clutch Cable assistance
Post by JOG on 11/26/24 at 09:42:38

If you ever remove enough stuff to get the oil pump drive gear off,mark it. It's easy to get on bakkerds. And it doesn't work that way.
How many miles on it?
Measure the cam chain tensioner,anyway.
It's also possible to get the oil filter in bakkerds. It's nearly always a Fatal Engine Medical Emergency.

Title: Re: Clutch Cable assistance
Post by ThumperPaul on 11/26/24 at 10:01:57

I guess you'll find out when you get in there. I guess it's possible for the clutch cam to become damaged by snagging yourself on the clutch lever, but it doesn't seem likely to me.

While your in there, check everything you can. You'll be staring right at the cam chain tensioner. If that sucker is extended 17mm or more, get a Versy cam chain tensioner with 2 holes. Pic of a Versy 2-hole CCT. The plunger is completely compressed in using the 2nd hole on the Versy CCT; when before installing it the standard CCT was poking out 17mm. Once that thing hits about 22mm extended, it goes boing, flies out, and torpedos your motor.

Title: Re: Clutch Cable assistance
Post by ThumperPaul on 11/26/24 at 10:19:10

Here's a pic of the clutch release cam setup. Make sure the spring is captured as shown in the photo (in the little groove).

Title: Re: Clutch Cable assistance
Post by ThumperPaul on 11/26/24 at 10:23:15

Photo of the release arm from the inside. Make sure to install the cotter pin so it doesn't bind up weird.

Title: Re: Clutch Cable assistance
Post by ThumperPaul on 11/26/24 at 10:26:01

Check the "flats" of the release arm. If the "corners" are rounded off badly, you'll want to replace the release arm.

Mine looked "ok". Not great. Not terrible. If wasn't causing issues, so it got reinstalled.

Title: Re: Clutch Cable assistance
Post by Samhines6 on 11/26/24 at 10:58:58

Sheesh, you guys are thorough (and fast)!

JOG: I think she's sitting around 12k at the moment, it's a 06 if that matters. I'll be sure to give the CCT a measure while I'm in there.

Thumper Paul: Very cool, I greatly appreciate the pictures & guidance. I'll for sure be referring back to this when I get her opened up.

Title: Re: Clutch Cable assistance
Post by ThumperPaul on 11/26/24 at 11:57:13

That's just a cursory overview. Everything I know about these bikes, I've learned from the awesome guys on this forum.

Here's a pic of the OEM CCT at 17mm (notice - just 1 hole and no "plunger stopper"). Gives you an idea where to measure.

Title: Re: Clutch Cable assistance
Post by ohiomoto on 11/26/24 at 12:11:06

6755595C5D5A514702340 wrote:

...I gave it a solid yank by accident and stripped the tension screw on the clutch lever.

-------------

Is this the "tension screw" you mentioned?

http://https://cdn.partzilla.com/cdn-cgi/image/width=320,quality=webp,fit=scale-down,format=auto/MTE/pi/d/MTA2NDkwMTg-d433c2e8.jpg

Title: Re: Clutch Cable assistance
Post by Samhines6 on 11/26/24 at 12:25:37

Ohiomoto: correct. That thingy.