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

Kirurgi

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Bike won't turn over and clutch does not work.
08/09/22 at 12:37:42

So I'm building my bike and now I have couple problems. First of all the bike won't turn over. Nothing clicks or happens when I try to start it. I measured wirings and i get good readings from starter relay +/- and from starter + to relay - but nothing from starter +/ground (frame). Start button and kill switch works also when measured. I have neutral light ok and even jumped side stand switch but nothing. Where to next?

Second problem is clutch. I changed clutch plates and now when everything is back on their places and oil is in I can change gears without pushing clutch lever and when lever is pulled and any gear is in it won't let the tyre roll freely. What is wrong?

Thanks for your help.

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28996 L.A. California Gender:	Re: Bike won't turn over and clutch does not work. Reply #1 - 08/09/22 at 12:47:16 no clicks, then it's the safeties.
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Kirurgi YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 24	Re: Bike won't turn over and clutch does not work. Reply #2 - 08/09/22 at 20:25:09 Thanks. Need to find a way to close them one by one. Any ideas for clutch? When I put all together outer or inner hub did not rotate by hand.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28996 L.A. California Gender:	Re: Bike won't turn over and clutch does not work. Reply #3 - 08/09/22 at 20:42:43 Follow the volts. push the button, should get 12v or so on 1 of the wires leading to the clutch safety. a manual will help find which wire is which. pull the decomp controller, 1 wire should light up when the button is pushed. and of course push the button and 1 wire should light up on the starter relay.
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Kirurgi

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Re: Bike won't turn over and clutch does not work.
Reply #4 - 08/16/22 at 07:49:48

"Second problem is clutch. I changed clutch plates and now when everything is back on their places and oil is in I can change gears without pushing clutch lever and when lever is pulled and any gear is in it won't let the tyre roll freely. What is wrong?"

So I rolled the bike out from garage. I can change gears without pulling the clutch lever. On neutral it rolls good but when I hit 1st gear in and pull the clutch lever it won"t disengage clutch plates and let me roll. When cover is Off and I try to rotater outer or inner hub of the clutch they don't rotate. Its stuck.

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buster6315 Senior Member Offline SuzukiSavage.com Rocks! Posts: 384	Re: Bike won't turn over and clutch does not work. Reply #5 - 08/16/22 at 08:00:25 Sounds like the clutch plates are stuck together, or the mechanism that disengages the clutch is not assembled properly.
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Kirurgi YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 24	Re: Bike won't turn over and clutch does not work. Reply #6 - 08/16/22 at 08:26:46 Well need to open it again. I assembled it 2 times allready by the book / videos. Still same problem. I can pull the lever and it feels stiff / tight but it does not disengage plates.
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verslagen1

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Re: Bike won't turn over and clutch does not work.
Reply #7 - 08/16/22 at 08:46:09

Kirurgi wrote on 08/16/22 at 07:49:48:

"Second problem is clutch. I changed clutch plates and now when everything is back on their places and oil is in I can change gears without pushing clutch lever and when lever is pulled and any gear is in it won't let the tyre roll freely. What is wrong?" So I rolled the bike out from garage. I can change gears without pulling the clutch lever. On neutral it rolls good but when I hit 1st gear in and pull the clutch lever it won't disengage clutch plates and let me roll.

by hand, lift the lever on the case. where is it with regards to the marks on the case?

Quote:

When cover is Off and I try to rotater outer or inner hub of the clutch they don't rotate. Its stuck.

This is normal. without pushing clutch throwout rod in (which is pretty hard to do) inner and outer are stuck together.
If you remove the spider, then they'll turn.

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Kirurgi YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 24	Re: Bike won't turn over and clutch does not work. Reply #8 - 08/16/22 at 22:31:40 Here is the pics. Fist is at rest.
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Kirurgi YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 24	Re: Bike won't turn over and clutch does not work. Reply #9 - 08/16/22 at 22:32:12 Second when lifted with finger.
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Kirurgi YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 24	Re: Bike won't turn over and clutch does not work. Reply #10 - 08/16/22 at 22:33:43 Third from inside.
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Kirurgi YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 24	Re: Bike won't turn over and clutch does not work. Reply #11 - 08/17/22 at 01:54:55 Clutch worked fine before I opened it and changed plates.
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DragBikeMike

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Re: Bike won't turn over and clutch does not work.
Reply #12 - 08/17/22 at 03:20:26

Your second picture shows the release lever is too high when lifted with your finger. The lever needs to be right between the two marks.

As the clutch wears, the lever gets lower. You replaced all the worn clutch parts. That will cause the lever to get higher. You probably need a longer pushrod (they come in three different lengths). Of course, this assumes that the clutch is assembled correctly.

It would help if you could post some photos of how you have assembled your clutch. Take some pictures of how you stacked up the plates, how you installed the wave washer assembly, how you have the thrust washers and sleeve installed, etc.

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Kirurgi

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Re: Bike won't turn over and clutch does not work.
Reply #13 - 08/17/22 at 04:35:18

I will take new photos after I open it again. This is how i assembled it (pic). Seat washer and then that curved washer (outer upper ring side thowards plates). Then the fat friction plate so its first plate from outside. Then the rest friction and driven 1 by 1. I will get back to this asap I get it open again.

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Kirurgi YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 24	Re: Bike won't turn over and clutch does not work. Reply #14 - 08/18/22 at 03:33:56 Here is the pushrod. 45mm.
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