SuzukiSavage.com - Clutch Cable assistance

Samhines6

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Clutch Cable assistance
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

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JOG Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2052 Longview, Texas Gender:	Re: Clutch Cable assistance Reply #1 - 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.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18313 Camp Springs, Kentucky Gender:	Re: Clutch Cable assistance Reply #2 - 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).
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Samhines6 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 9	Re: Clutch Cable assistance Reply #3 - 11/25/24 at 16:58:02 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. Dave: it was between the lines before I started messing with things, yes. Attached a picture of the engine-side connectors.
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Samhines6 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 9	Re: Clutch Cable assistance Reply #4 - 11/25/24 at 17:05:44 Don't judge my scrap battery door too harshly
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JOG

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Re: Clutch Cable assistance
Reply #5 - 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.

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Samhines6 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 9	Re: Clutch Cable assistance Reply #6 - 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? 👇 https://www.partzilla.com/product/suzuki/23263-24B01?
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JOG Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2052 Longview, Texas Gender:	Re: Clutch Cable assistance Reply #7 - 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.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18313 Camp Springs, Kentucky Gender:	Re: Clutch Cable assistance Reply #8 - 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.
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JOG Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2052 Longview, Texas Gender:	Re: Clutch Cable assistance Reply #9 - 11/26/24 at 04:24:38 Dave, why do you have an engine sitting on a bench?
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Dave

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Re: Clutch Cable assistance
Reply #10 - 11/26/24 at 04:48:13

JOG wrote on 11/26/24 at 04:24:38:

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!

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Samhines6

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Re: Clutch Cable assistance
Reply #11 - 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.

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Dave

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Re: Clutch Cable assistance
Reply #12 - 11/26/24 at 07:01:04

Samhines6 wrote on 11/26/24 at 06:10:04:

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.

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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2152 Houston, Texas Gender:	Re: Clutch Cable assistance Reply #13 - 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!
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Samhines6

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Re: Clutch Cable assistance
Reply #14 - 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 Shocked

Guess that'll give me an opportunity to get comfortable with the clutch system (hurray optimism!).

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