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Clutch Cable assistance (Read 109 times)

JOG Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2052 Longview, Texas Gender:	Re: Clutch Cable assistance Reply #15 - 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.
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ThumperPaul

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Re: Clutch Cable assistance
Reply #16 - 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.

Verslavy_CCT_002.jpeg

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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2152 Houston, Texas Gender:	Re: Clutch Cable assistance Reply #17 - 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).
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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2152 Houston, Texas Gender:	Re: Clutch Cable assistance Reply #18 - 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.
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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2152 Houston, Texas Gender:	Re: Clutch Cable assistance Reply #19 - 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.
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Samhines6 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 9	Re: Clutch Cable assistance Reply #20 - 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.
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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2152 Houston, Texas Gender:	Re: Clutch Cable assistance Reply #21 - 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.
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ohiomoto Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2825	Re: Clutch Cable assistance Reply #22 - 11/26/24 at 12:11:06 Samhines6 wrote on 11/25/24 at 15:04:57: ...I gave it a solid yank by accident and stripped the tension screw on the clutch lever. ------------- Is this the "tension screw" you mentioned?
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Samhines6 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 9	Re: Clutch Cable assistance Reply #23 - 11/26/24 at 12:25:37 Ohiomoto: correct. That thingy.
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