SV650S K6 clutch mechanism worn?

[aesmith]

Cheers. I'm pretty sure it's the release mech causing the issue. With it all cleaned up and lubed, you can see the first rotation of the lever just causes axial movement of the worm, only once that's taken up does it actually push.

[aesmith]

Update, I've replaced the mechanism with a supposedly genuine Suzuki part and I must say I'm pretty disappointed. The new mechanism has almost as much play and lost motion as the old one. I don't know if they're all that bad, or whether I have a dud unit.

To explain, clearly you want to fit the mechanism so that when it's at rest the lever is fully to clockwise with the "worm" fully retracted. That minimises the amount that the worm extends when the clutch is operated. Mine has two problems, firstly set like that the return spring is not under tension, meaning that it doesn't necessarily pull back freely. Secondly the first 5mm or so of cable movement just takes up axial play in the worm and does no pushing at all. That's quite a sizeable proportion of the handlebar lever travel, putting the biting point when the lever's pulled in maybe 3/4 of it's travel.

This video shows (first 10 seconds) the free play shown by wobbling the arm towards and away from the engine, the last part shows the cable and actuator travel before any actual working movement.

http://youtu.be/NQ7eOViuFVg

First question - does this look like I've got a dud?

Second question, how best to use it. I can get the lever travel and biting point about right by taking up the lost motion by tightening the cable. The problem with this is that the final freeing of pressure on the push-rod is uncertain, determined by cable tension.

Any suggestions welcome.

Tony S

[Bibio]

http://forums.sv650.org/showthread.p...utch+adjusting

[aesmith]

Originally Posted by Bibio

http://forums.sv650.org/showthread.p...utch+adjusting

Thanks. I did see that prior, but I'm not sure it says anything relevant to my particular question. The adjustment process she presents is exactly the process I followed.

You think my mechanism is normal I assume, and I should just tighten up the cable until it works.

[Red ones]

The screw adjustment in the middle needs tightening. That's the bit with a quarter to one eighth turn to do.

[Red ones]

It's item 3 and 4 on the link given above.

[Bibio]

well if i didn't know better i would say there are bearings missing. did you but it from a suzuki dealer?

[aesmith]

Originally Posted by Red ones

The screw adjustment in the middle needs tightening. That's the bit with a quarter to one eighth turn to do.

Cheers, I've done all that. The screw adjustment isn't relevant to the free play shown in the video, as the mechanism hasn't started pushing yet. Edit If I tighten the screw further then it will be be pressing on the push rod all the time which would not be good.

[aesmith]

Originally Posted by Bibio

well if i didn't know better i would say there are bearings missing. did you but it from a suzuki dealer?

I actually took it off to check. There's not much more play in my old one which does have balls missing.

It was bought by mail order as new genuine Suzuki part, not sure if the seller is a Suzuki dealer but the part came sealed and branded. Do people make fake Suzuki bits (as opposed to pattern)?

[Red ones]

There is a well known supplier from north london that I bought mine from recently. It was a genuine part, I was surprised at how much i had to adjust it