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problem with clutch

Started by manoj, October 28, 2009, 07:48:10 PM

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manoj

started the bike,warmed it up for a min and then the clutch wont disengage....when i pressed the clutch hard it kinda snapped but when i pulled the cable from the lever end the cable is not coming out.what may be the problem
Has the clutch cable snapped?
or is something else wrong with it
gonna open it up tomorrow and see what wrong so need a heads up  what to expect..
Manoj

The Buddha

You're saying it felt like the cable snapped from lever feel, but the cable isn't snapped ...

If that is the case, get someone to give you the suzuki clutch switch designer's home address, and you go over there with a baseball bat and bash him till he says he's sorry for putting the world's shiettiest clutch switch in this bike.

Bypass the POS by shorting the yellow wire with green tracer onto itself. It is in the headlight bucket.

Worthless crap. You bypass it and remember to pull the clutch before you put it in gear ... and when you stall it ... well dont start it in gear wihtout the clutch in ...  :cookoo:
Cool.
Buddha.
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elementguy053

My clutch was really hard to pull in and eventually wouldn't disengage the clutch.. I opened the small adjustment cover on the left side and found a couple of ball-bearings in there, probably from the lifting mechanism. I'm still waiting a new lifting mechanism. Something to check.

manoj

Hi Buddha
The switch is fine but the cable would not go in or when try to pull out,but after reading your message went back and checked the bike it is working properly now again.Before the cable had come out(to about the position when the lever is fully pressed) but now after about an hour or so the cable has gone back to the normal position and is working properly.Need to check this lifting mechanism like elementguy053  suggested.
Manoj

tt_four

I know you already fixed it, but for future reference.... my first guess was that the engine end of the cable popped out of the little peice it attaches to. When you pull off that engine cover there's a little slot you slide the cable in to, and then you just bend a little metal tab to keep the cable from falling out. I'm a little apprehensive to bend that part back and forth too much considering my bike is 18 years old, so i usually only bend it half way, and if I'm not careful until I get tension on it, it will fall out. This would take away any feel when you pulled the lever, but the cable still would not pull out of the engine, kind of like you described.

Mine also worked fine when i got my bike rebuilt, but after starting it twice briefly, and then letting it sit for a month or two, my clutch is acting goofy again. No matter how I adjust it, I can't make the clutch fully disengage when I pull the lever in. Even with the lever pulled all the way in the bike is still 50% in gear and it's a ton of work if I'm trying to move the bike around when it's in gear. That'll be a winter project.

manoj

today the clutch just would not disengage ,then opened the side cover and found the fault to be with the cable.The cable was stuck solid in the sheathing and would not move in or out when i tried pulling it by hand
what would have caused this.... rust/snapped cable.
Manoj

elementguy053

It's most likely dirt and grime that have gotten into the sheath. You're supposed to lube it pretty regularly (with wd40 or the like).

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