Re: Rapid clutch wear
 

Ta for the help. I'll get one ordered. Fortunate that we've managed to diagnose it before it's critical :)

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Re: Rapid clutch wear
 

Ok a bit more advice required.

I've ordered a new part. In the meantime I've found that if I adjust the worm drive so that it touches the clutch rod, I gain a bit more adjustment in the clutch lever/cable.

ie I've followed Sid's oft quoted advice, but not wound it back a bit.

Is this OK or is it a common noob mistake that's gonna bring me a world of hurt? Can I leave it like this for a while or should I fit the new part as soon as possible?

Re: Rapid clutch wear
 

it might let the clutch slip when giving the bike beans. i adjust mine pretty much like that but i leave a wee bit play, say 1/8 of a turn.

Rapid clutch wear
 

It will probably be OK as long as you set it so when it's completely cold. You've probably noticed that the lever gains a little slack when the engine is hot, so as a short term expediency set as you have it shoudn't be over tight. Obviously the lifter needs a dab of slack to make sure that the clutch is completely free to operate at all temperatures.

Re: Rapid clutch wear
 

Can't say I had noticed it gaining slack when hot. It gains slack constantly on my bike! Anyway, yes it was set that way when cold. Surprising how much extra adjustment it gives, but I suppose that's the nature of a worm drive.

Re: Rapid clutch wear
 

it should not be doing that even with worn plates or knackered worm gear. have you checked the condition of the clutch cable for fraying especially at the lever end?

Re: Rapid clutch wear
 

No need to worry Bibio - that was the original problem and turned out to be the adjuster vibrating loose at the lever end. I couldn't tighten it properly because there wasn't enough thread left in the hole. Now I've gained more adjustment by removing the eighth-turn slack on the pushrod and it's gained me enough thread at the lever to tighten the locking nut sufficiently.

I think it's now fine :) New lifter on the way anyway.

Re: Rapid clutch wear
 

Just to close off this thread, part arrived and has been fitted and all is well again.

For anyone else with the same problem, the part is 23200-11D00 and Suzuki call it a Clutch Release Screw. £45.50 from http://www.robinsonsfoundry.co.uk/

Very simple to fit.

Incidentally I saw 2 on ebay second hand for around £40. Seemed a bit pointless.