Clutch adjustment - Suzuki SV650 Forum: SV650, SV1000, Gladius Forums

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Old 08-08-2019, 07:49 PM   #1
RIDER675
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Clutch adjustment

Ive posted about this same problem before I think? Suspect somethings up with my clutch because I cant adjust it properly. Which way do I turn the mechanism to make it easier to shift? Clockwise I thought? Think ive tried every possible position on the damn thing today, from out none to about 1/2 turn. Only one very specific position seems to work but I had trouble downshifting. Supposed to be loaded up for a trackday atm
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Old 08-09-2019, 12:03 AM   #2
RIDER675
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Re: Clutch adjustment

Somethings not right, while the adjustment isnt random there isn't a trend going one direction or the other. Adjustments are repeatable only just, because its sensitive to 1mm adjustments. Going to rebuild the worm gear tomorrow in case its put together wrong. When the clutch is starting to engage I can hear it knocking, is this a sign of anything?
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Old 08-09-2019, 05:58 AM   #3
Straticus
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Re: Clutch adjustment

I went through this when I got my Curvy and made a page of the work I did,

https://cx500.000webhostapp.com/SV650ClutchLifter.html

as I had trouble getting into neutral.I tried a new,"Slinky Glide" cable which I had used on other bikes but the Metal curved guide had a tighter radius and bound causing the lever to be stiff.Went back the the original,no problems.
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Old 08-09-2019, 10:48 AM   #4
RIDER675
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Re: Clutch adjustment

Quote:
Originally Posted by Straticus View Post
I went through this when I got my Curvy and made a page of the work I did,

https://cx500.000webhostapp.com/SV650ClutchLifter.html

as I had trouble getting into neutral.I tried a new,"Slinky Glide" cable which I had used on other bikes but the Metal curved guide had a tighter radius and bound causing the lever to be stiff.Went back the the original,no problems.
Good info, I switched to a race cable without metal bends because the originals would split after a few days. Depending how it's adjusted it can shift, but the pull is ridiculously heavy. If I leave 3mm play at the lever for instance, but if I set free play to 4-5mm the bike creeps forward in gear, no matter how its adjusted.

Made sure the worm gear was together properly already, your page was very helpful also for my other sv. Guess ill try the original cable.
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Old 08-09-2019, 03:31 PM   #5
RIDER675
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Re: Clutch adjustment

Suspect an internal clutch issue, also hearing knocking as I let the clutch out. Any idea where to start?
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Old 08-09-2019, 04:23 PM   #6
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Re: Clutch adjustment

mine has a low clunk when i let the clutch out in neutral
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Old 08-09-2019, 06:30 PM   #7
RIDER675
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Re: Clutch adjustment

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Originally Posted by nicks-sv View Post
mine has a low clunk when i let the clutch out in neutral
It's a rhythmic hollow knock that slows as the clutch is let out in gear.
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Old 08-09-2019, 07:54 PM   #8
nicks-sv
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Re: Clutch adjustment

i can only hear it in neutral, i pull the clutch in and it goes away. low rythmic clunk or muffled knock. like the previous owner revved it up and dumped the clutch. maybe the clutch basket got twisted.
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Old 08-10-2019, 12:12 AM   #9
jksh25
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Re: Clutch adjustment

I would do a visual inspection of the clutch basket. It only takes 20 minutes. Remove the clutch cover. Do a quick check of clutch bolt tightness.

Then remove the stack of friction and slick plates (keeping them in order slick/friction/slick/friction/etc) and pay attention to 1) discoloration (overheating), 2) warped discs, 3) smoothness of slots and teeth of basket and discs, and 4) no damage to springs or pressure plate.
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Old 08-10-2019, 02:54 PM   #10
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Re: Clutch adjustment

Think about what you are trying to accomplish when adjusting the clutch: you need enough free play to allow the springs to compress the plates without any pressure loss to the disengagement mechanism.....while allowing the clutch lever to disengage the plates far enough so they don't drag. The easiest way to go about it is to just make sure you have a little free play when the lever is fully released (both at the clutch release mechanism as well as the lever itself) and then whatever pressure it takes to pull the lever is all in the clutch springs with the added drag (which should be minimal) of the cable friction.

If it's difficult to shift that sounds like the clutch isn't disengaging......which could either be improper adjustment or something mechanical internally preventing the clean release of the plates. Once you have the free play at the worm drive adjusted so it's adequate to ensure full engagement...but only a wee bit so the clutch lever movement can press the plates apart as far as possible....if it still drags then you have an internal problem.
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