SV650S K2 Clutch actuator problem(?)

I've just bought a used (second-hand) SV650s K2 with 29000km. When I bought it I noticed that the clutch lever slag was big. I tensioned the clutch cable and I adjusted the nut-screw on the actuator (now the clutch lever has the proper slag) but even with the lever fully pulled the bike tends to move (it doesn't declutch)! I suspect that the actuator is worn out.

-What is your opinion?
-Is it a part that wears out a lot in sv?
-Can I trust clutch actuators in ebay or it is a tricky buy?
-What is the price of a new actuator?
-If I remove the actuator can I open it or do anything to check If it is really worn out?
-Is it difficult to replace the part on my own, or is it a simple procedure?
-Is the actuator from SV650 K3- the same, can I use it instead of the original?

[Sid Squid]

Originally Posted by ssurprize

-What is your opinion?

It's knackered.

Originally Posted by ssurprize

-Is it a part that wears out a lot in sv?

They are known to wear, yes.

Originally Posted by ssurprize

-Can I trust clutch actuators in ebay or it is a tricky buy?

I wouldn't buy a second hand one without checking it first - I wouldn't be surprised to find a used one as worn as the one you already have.

Originally Posted by ssurprize

-What is the price of a new actuator?

Where are you? I think they're about £35 in the UK.

Originally Posted by ssurprize

-If I remove the actuator can I open it or do anything to check If it is really worn out?

No need to remove it, adjust it carefully then try to move the arm that the cable pulls up and down, if it moves more than a few millimetres it's worn.

Originally Posted by ssurprize

-Is it difficult to replace the part on my own, or is it a simple procedure?

Very easy, just two bolts, then adjust it and set the cable slack correctly.

Originally Posted by ssurprize

-Is the actuator from SV650 K3- the same, can I use it instead of the original?

They're the same on every model of SV650, part number 23200-11D00.

Thank you! You've given me a very thorough and helpful answer. I live in Greece and just called the official Suzuki dealer on the phone to ask the price of this part, they told me 33 euros.

Does anyone have the parts list to send me (or can advice me on how to get it) either by email or link?

[Sid Squid]

You're welcome, .

Originally Posted by ssurprize

Does anyone have the parts list to send me (or can advice me on how to get it) either by email or link?

Look here.

And now I wonder... How do I remove the clutch cable from the activator's arm?


edit: I just read in the manual somewhere: "If it is necessary to replace the clutch cable or clutch release lever, pry up and bend down the stopper (A) of the clutch release lever."
Could You please give me any practical idea of how to "pry up and bend down the stopper"?

[Sid Squid]

The lower nipple of the clutch cable is retained in the arm on the actuator it pulls by a small tang being bent inwards, under the end of the nipple, (the hole in the front of the arm that you can see underneath where the cable enters the arm).
Use a small screwdriver and insert it under the bottom of the nipple, give it a twist and the tang will easily bend downwards allowing you to slide the nipple out of the slot.
If you remove the two bolts that hold the actuator and turn it around so you can see into the end of the arm it should be obvious - you may have to clean it a bit first! Also you will notice that the new actuator's tang is still flat against the side of the lifter arm - it's not bent inwards yet.

It's held so in order to prevent it from disconnecting from the arm it pulls if there is excess cable slack, but they're often broken off and as long as the clutch is something like correctly adjusted it won't come adrift.

Alright but could you please propose to me a practical way to bend that thing in order to release the clutch cable?
The code of the clutch cable is 58200-19F00 ??? How easy is to replace the cable? Can You give me some instructions please? Is it needed to raise the tank or remove the airbox?

[Sid Squid]

Originally Posted by ssurprize

Alright but could you please propose to me a practical way to bend that thing in order to release the clutch cable?

Yes:

Originally Posted by Sid Squid

Use a small screwdriver and insert it under the bottom of the nipple, give it a twist and the tang will easily bend downwards allowing you to slide the nipple out of the slot.
If you remove the two bolts that hold the actuator and turn it around so you can see into the end of the arm it should be obvious - you may have to clean it a bit first! Also you will notice that the new actuator's tang is still flat against the side of the lifter arm - it's not bent inwards yet.

Originally Posted by ssurprize

The code of the clutch cable is 58200-19F00?

Correct.

Originally Posted by ssurprize

How easy is to replace the cable?

Very.

Originally Posted by ssurprize

Can You give me some instructions please? Is it needed to raise the tank or remove the airbox?

You'll need to raise the tank in order to make it easy to thread the cable into place, you won't need to remove the airbox.
Turn the adjusters top and bottom of the cable, so that there is the most amount of cable slack, disconnect the lower cable nipple from the lifter as above, at the lever align the slots in the adjuster and the locknut so that the cable can be removed from the adjuster, twist the cable inner forward until it aligns with the slot in the lever and remove the nipple from underneath the lever. Remove the cable noting its routing, and thread the new one into place, connect as a reverse of the removal, then:

Originally Posted by Me! Lots

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 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.