Longer clutch cable adjuster?

[ChrisCurvyS]

Does anyone know if there is a longer clutch cable adjuster (the one at the lever end) which will fit a Curvy?

Basically, I've run out of adjustment at both ends (cable stretched perhaps) and I'm at the stage where I have to have the lever end adjuster so far out, I can't tighten it properly and it keeps popping out with the cable. Screw the adjuster into the housing any more and it's a massive struggle to change gear and impossible to get it in neutral. Tried doing the full adjustment process but doesn't seem to sort the problem.

I expect a longer adjuster would do the trick (at least as an interim measure - riding to Ireland on Friday) and expect they're pretty standard across Suzukis, but not had any joy finding one through Google or this site.

[TamSV]

If you're certain everything else is in good condition and you're at the maximum adjustment, you need to get a new clutch cable.

If you stretch it any more it's going to go ping at some point. A clutch cable's not too horribly expensive.

[Sid Squid]

I'd be very surprised if the cable could stretch enough to outgrow the available adjustment - I'm sure it would break first.

I'd put money on the lifter needing adjustment, like this:

Slacken off cable adjusters at top and bottom, loosen lifter locknut, back out screw a bit, ensure that lifter arm is as far down as it will go, gently turn screw in until it contacts pushrod, back it out a bit, (~1/8th of a turn), then nip up the locknut, roughly adjust cable with lower adjuster - not too tight - then with top adjuster ensure that there remains a little slack all the way from lock to lock.

[ChrisCurvyS]

Yeah I will do that as soon as I'm back from Ireland - it's just I'm a bit short on time and daylight to fit a new cable between now and then and I'm screwed if I mess anything up while fitting it. (I'm that crap a mechanic, anything's possible)

Good point about it snapping though - think I'll buy one and take it with me in case it does go while I'm over there. Perhaps a little piece of tubing with a cut down will do the trick for now.

Ta for that.

[ChrisCurvyS]

I'd be very surprised if the cable could stretch enough to outgrow the available adjustment - I'm sure it would break first.

I'd put money on the lifter needing adjustment, like this:
Yeah Sid I've gone through all that a few times - it's the same instructions as in the Haynes isn't it?

So you don't think it could be a stretched cable? Whoever posted this describes exactly the same thing -

http://www.bluepoof.com/motorcycles/howto/svs_clutch_cable/

[Sid Squid]

I've yet to encounter an SV that's run out of adjustment when the, (non-knackered), lifter is set right. I'm not going to promise you it couldn't ever ever possibly happen - but I'd be surprised.

[ChrisCurvyS]

I;ll give it another try then - recall the lifter bit is very delicate so may have cocked up there. I;ll go through it all again. Thanks for the info - big help.

There is an upside to all this though - it was quite exciting filtering at about 50mph as i couldn't get out of fifth.

[ChrisCurvyS]

Well too the front sprocket cover off and it turns out the three-piece widgety thing which surrounds the nut around the screw in the clutch adjustment mechanism has popped out. Can push it back in but it will slide out again after a few pumps of the clutch.

Tried adjusting the clutch several times but couldn't seem to do it without either the change being clunky and forced or the clutch slipping under power. Whether or not the two are related I don't know.

Will try again tomorrow in the work car park - ran out of time tonight with the neighbours, plus our drive opens on to a fast nsl road just after a blind bend so not ideal for testing a slipping clutch.

Sid - you don't know what the thing I described is do you? Couldn't see anything to identify it in the Haynes manual...

[Sid Squid]

I'm not sure what it's referred to in the Haynes, but it's the part I've been referring to as the lifter. It's the arm and screw mechanism that turns the pull of the cable into a push of the rod - I'm sure you're very well aware of this, but just so we're not talking at cross purposes.
And it sounds as if something is amiss as it definitely shouldn't be possible for it to be pulled/pushed in and out of place. It should be possible only for it to turn and in doing so move back and forth. It may be worn or perhaps simply missing the ball bearings upon which it twists.

[ChrisCurvyS]

Ah so that's the lifter itself - thought it was some peripheral part of the mechanism as it's just a sort of sleeve around the screw and nut, but I suppose that would explain the trouble.

I don't want to bore you with the detail but some sort of thin rubber gasket also came off the back of it and the whole area was infested with grit which may well have penetrated the moving parts, so expect I might need some new bits.

Thanks for the guidance Sid - much appreciated.

[Sid Squid]

I don't want to bore you with the detail but some sort of thin rubber gasket also came off the back of it and the whole area was infested with grit which may well have penetrated the moving parts, so expect I might need some new bits. Grit? Check. Loads of it usually. The rubbery bit is intended to keep the gritty stuff out and the greasy stuff in. Occasionally it does.
Thanks for the guidance Sid - much appreciated.You're quite welcome - that's what we're here for!

That's the good news, the bad news is that from what you relate I suspect the lifter has shuffled off it's mortal coil. A new one, part number; '23200-11D00 Clutch Release Screw' is about £45, see here: Click me! (http://www.robinsonsfoundry.co.uk/content/pages/home/advanced-search.htm?search=23200-11D00&search_products=yes&search_pages=yes&search_groups=yes&search_new_bikes=yes&search_used_bikes=yes&match=all_words&submit.x=15&submit.y=11)

There remains the possibility that the lifter has simply lost it's bearings, (did you see what I did there? :) ), and if you feel confident to take it apart and examine the screw tracks you may possibly be able to replace just the balls, (bicycle shops are good for such things), but if you're unsure of it's condition a new one is an easy way to make sure it's right of course.

[ChrisCurvyS]

Sid - you're a true gent. 'Lost its bearings' - I like it, also thought the mortal coil bit sounded like it should have been a pun.

Think I'll do more harm the good if I try and replace the balls so I'll get a new one - won't arrive for at least a week though so I'm going to tinker with the adjustment and hope I can get to Galway and back with it. It's pretty much all motorway and dual carriageway though so won't be using the clutch much.

Apart from getting on and off the ferry of course - but what's the worst that could happen?!