Gear/nautral issues

[simon1]

Hi
My 2001 K1,carby is getting quite hard to find nautral when I stop and quite hard to get into gear....have played around with the clutch adjuster,and this eitherss seems to have to much and the clutch slips,or not enough.....ive heard that new oil can be of benefit..and also adjusting the chain?...but is the chain issue because its to tight or lose?

Thanks

[andy650]

Check its not the gear lever, disconnect from change shaft (mark spline position) and check everything is smooth and free (lever pivot, 2 rose joints)

3-5mm play on clutch lever, use adjuster to set.

Chain needs to be right, too tight is worse.

When above is correct, does bike try to creep at all when in first and clutch fully pulled in?

If not, how far do you have to release the lever for it to start creeping?

[maviczap]

Search for clutch adjustment on here, that's your problem here.

Not just at the cable, but adjust and cleaning of the accutator mechanism behind the sprocket cover.

Cleaning the pushrod too.

[simon1]

Thank you......does the accutator mechanism come apart?...is there a disagram anywhere?...sorry I don't have a manual

[maviczap]

Thank you......does the accutator mechanism come apart?...is there a disagram anywhere?...sorry I don't have a manual

Yes, and spreads thousands of ball bearings when you take it apart!

I can't remember seeing any pictures or diagrams.

I'll see if I can find my workshop manual and post up how to service it

[simon1]

that would be great thanks

[DuncanC]

The actuator is a plastic contraption that you can get apart but even if you can find all of the ball bearings the plastic is usually worn out. A new one is normally the only long term solution.

[maviczap]

Right here's the adjustment procedure for the mechanism after removing the sprocket cover.

As Duncan says better to buy a new one rather than clean insides of the old one.

However, before you buy a new one, do this. Take the sprocket cover off, give the whole area behind a really good clean. Remove the mechanism, clean the outside, remove the push rod and give that a good clean too.

Put it all back together and adjust as per the manual says, if it doesn't help, then buy a new mechanism, thats after checking chain tension & making sure your oil level isn't too high

https://farm5.staticflickr.com/4658/39619295851_29e748fecb_b.jpg (https://flic.kr/p/23n2fkM)sv clutch (https://flic.kr/p/23n2fkM) by maviczap (https://www.flickr.com/photos/89416312@N07/), on Flickr

[simon1]

Hi
That's great info...thank you very much......if I need to buy a new one...where is the best place...is there a part number....thanks

[maviczap]

Here

http://www.robinsonsfoundry.co.uk/pages/home/advanced-search.htm?search=23200-11D00&is_posted=yes&submit.x=9&submit.y=5#tabs|Search:parts

[johnnyrod]

I've found they last about 20,000 miles so if you're near or over that then don't be surprised if the action isn't great even after adjustment. DON'T take it to bits. Certainly sounds like classic clutch drag to me.

[simon1]

Hi Thank you.....I did take it apart!.....and found the problem I think....the little bearings where broken!....would anyone know the size of the worm drive bearings,and where to get if possible.....thanks

[maviczap]

Hi Thank you.....I did take it apart!.....and found the problem I think....the little bearings where broken!....would anyone know the size of the worm drive bearings,and where to get if possible.....thanks

Don't bother just buy a new one or get a good used one from a breaker

The part number is shared by several models.

[simon1]

ok...sorry have you got the part number..i cant seem to find it...

[maviczap]

Right here it is 23200-11D00

Use this site to find the part number http://www.alpha-sports.com/suzuki_parts.htm

Once found, copy and paste it into the search function for UK price. In the drop down it shows the models that use the same part

http://www.robinsonsfoundry.co.uk/

[simon1]

Great thank you

[johnnyrod]

That's more expensive than I remember! Search the 'bay for "SV650 clutch worm" or "SV650 clutch lifter"

[maviczap]

Maybe, but I seem to recall other folk wincing at the cost of the new ones before ;)

[simon1]

trouble is if i buy secondhand it could be no better than the one I have

[maviczap]

trouble is if i buy secondhand it could be no better than the one I have

Yep

[johnnyrod]

Possibly. The problem I've found is that the plastic worm gets gouged by the ball bearings.

[garynortheast]

Worth just putting new one in. I bought one from Robinsons about 3 years ago for around £47, and the difference in the clutch operation made it worth every penny.

[timwilky]

I would also second the advice from Andy65 regarding the lever

It tends to corrode causing it to then bind to the shaft.

When removing, take care to compress the fibre bush to remove. They are not replaceable. a good scrub with emery cloth inside the bore, replace the bush and some light oil.