so I’m pretty sure the clutch on my bike is on its last legs, lever needs to be 3/4 of the way out before you feel it grab.  Now I’ve looked on line but can’t find a full kit replacement most places sell plates individually, and I THINK my bike only require five Friction plates(2008 suzuki s40) I’ve always just replaced the friction and steel plates and springs before.  

What do you guys recommend ?? I’ve seen cork style and Kevlar style friction plates.  I do tend to get a little wild with my shifting sometimes, I don’t granny shift it - I like to bang a few gears like most bikers do lol

I’ll have to check that tomorrow after work and see where the free play is on it.

Peter Fonda wrote on 05/27/25 at 17:13:12:


The Savage clutch is not very robust - you really should be a bit gentler to it. This is especially true if you have done anything to bump up the HP of the engine.

You should let your clutch completely out and let it engage fully before you apply throttle......don't start applying throttle while you are still releasing the clutch lever.  Your clutch and drive belt will appreciate the kindness!!!!!

I have the Kevlar plates in my bike currently - I really haven't noticed any difference in the performance.

Longevity is likely never to be an issue for me - I have only put about 1,000 miles a year on Savage.  (I ride a lot....but with 5 motorcycles the mileage on each one doesn't go up very quickly).

if you look at the case right below the arm you'll see a line and there's another one hidden by the arm.

the less freeplay you have, the more action you'll have.

1st and foremost... adjust the cable to minimize freeplay.
2nd look at the lines for an indication for a need of adjustment.
 the higher the arm is the more likely you'll need to change the throwout rod for a different 1.
 there are 3 lengths, they are not expensive, buy all 3. better to have an extra 1 then the wrong 1.

Here is a video on how to adjust the clutch cable.

For the bottom adjustment you use the 2 nuts near the cable end.

https://www.youtube.com/watch?v=8MW4h1Rk9AA


When that chrome lever at the engine rises enough that it is at the upper mark on the case - it is time to install a shorter rod inside the clutch.

Kind of hard to see but ya get it