How many miles did you have on the bike prior to breaking the cams? Did you only start breaking the cams "after" you installed new plates and springs?
The OEM clutch cam is a known weak spot and they can break - but breaking 2 in a short period of time is not normal. Most folks break them when they install stronger springs, washers or do something to make the clutch grab a bit harder.
On the side of the clutch cover are marks that indicate the proper position of the chrome release lever when the clutch is engaged (hand lever fully out). The lever on the side should be between the marks. Unfortunately with a broken cam you won't be able to know where the lever is until you put a new cam in.
When you install the new cam and put the cover on - there should be some freeplay of the lever. You should be able to move the lever a small amount before it engages the springs.
Also check the condition of the shaft that the slides onto. The flats should not have rounded edges and the cam should not have a lot of rocking movement. DragBikeMike has inserted a shim on his clutch rod to make the cam fit better.
I have attached a link to the thread that shows the shimming of the shaft.
(NOTE: There once was a batch of specially made clutch cams available that were much harder than the OEM ones that are made from pressed metal. Unfortunately Sneeze had a fire in his garage and all of the unsold ones were lost).
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1615547049/15
Pages: 1
