Constantly increasing clutch free play. Do I need to change the clutch plates? - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
DL650 and DL650A - 2004 to 2011 DL650 from 2004-2006 (K4-K6) and DL650 or DL650A from 2007-2011 (K7-L1)

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post #1 of 22 Old 09-02-2019, 05:55 PM Thread Starter
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Question Constantly increasing clutch free play. Do I need to change the clutch plates?

I have a DL650A 07 with 63.000 km. At around 50k I had noticed that I had problem switching to neutral when I was fully stopped and the clutch lever had a lot of free play before it would engage. So I used the adjuster nut on the lever to reduce the free play. That fixed the switching to neutral problem. I could switch all gears very smoothly now. But after about 3-4K kilometres I had to adjust it again. And then another 3-4k kilometres I had to change the cable because there was no more room for adjustment anymore. Since then I have adjusted once again and now at 63k it feels like it's time to do it one more time. The cable is new so I don't think it's the cable, and the old one upon inspection was also fine.

Someone suggested to me that it might be time to replace my clutch plates. Does this symptom really point to worn out plates? Is it normal to have worn out plates at 60k? Please note that I don't feel any slipping of the clutch at high or low revs.
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post #2 of 22 Old 09-02-2019, 06:13 PM
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Typically under normal driving circumstances at 63,000 KM's the clutch would not need replaced. But not know how the bike was ridden it hard to tell.
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post #3 of 22 Old 09-02-2019, 06:37 PM
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Did you do the adjustment under the primary sprocket cover?
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post #4 of 22 Old 09-02-2019, 07:14 PM
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Quote:
Originally Posted by nvr2old View Post
Did you do the adjustment under the primary sprocket cover?
This. Adjusting the cable is only one of the 2 adjustments you need to do. It's outlined in the service manual, or maybe there's a thread here on how to do it, it's simple. Do this before digging deeper. I adjust my cable pretty frequently, I like to keep the .5'' of play.

Not likely the plates are worn at 63K km, but possible depending on how you ride. I just recently had odd increasing and decreasing slack on my old Harley's clutch lever. Opened it up expecting big problems, but discovered only that the clutch nut had loosened up, just had to Loctite it and torque to spec. So strange things happen, start with the simple stuff first.
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post #5 of 22 Old 09-02-2019, 07:34 PM
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Sorry, I should have clarified, there's 2 adjustments under the sprocket cover. Adjusting the pushrod is one, but you can also adjust the cable down there if you run out of adjustment up at the lever.

2009 Wee Strom ABS (current)
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post #6 of 22 Old 09-02-2019, 08:07 PM
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Ad the same milage as yourself my gear changes started becoming difficult. You need to adjust not only the clutch cable, but the clutch activator as well.
See here:https://www.stromtrooper.com/v-strom...nt-help-2.html
https://www.stromtrooper.com/dl650-d...ml#post5259037
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post #7 of 22 Old 09-02-2019, 08:13 PM
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Quote:
Originally Posted by om28 View Post
It's outlined in the service manual, or maybe there's a thread here on how to do it...
Go to SVRider.com and look for Andy Augers Clutch Mantra. Best write up I have ever seen on this adjustment procedure.

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post #8 of 22 Old 09-02-2019, 11:55 PM
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First of all if your clutch is not fully releasing (dragging) that isn't clutch plate wear. If the plate wear worn out the clutch would slip, not drag. (At over 202.000 km the clutch on my 2006 DL650 was working fine.


Make sure nothing is stopping your clutch lever from being fully pulled back. Is anything interfering?

Now if your clutch is dragging make sure you have the proper slack in your cable. This is done with the adjusters at either end of the cable.

If that doesn't work take a look at the clutch adjuster which is under the front sprocket cover. Check that it is adjusted properly. If it is adjusted correctly you might want to check and see if the actuator lever has play. I had the spot weld that holds the actuator lever break and that gave symptoms like yours (OP). See if that lever has play. If it does you need to replace it and it isn't a ton of money. (I don't know if you can just spot weld it again to secure it ).

If none of those fix the issue you might also look at the pivot the clutch lever pivots on. Is everything there okay? Loose bolt or excessive wear can cause problems. (I haven't talked about fraying ends of the cable since you replaced the cable an that didn't fixe the problem )

..Tom
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My Opinion:
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Vee3 or V3 = DL1050 2020 to?

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post #9 of 22 Old 09-03-2019, 01:12 AM
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I had that symptom on a dirt bike many years ago. Turned out to be the cable started to go. A few of the strands had broke loose causing the cable to stretch.
Modern, lined cables can get stiff when the inner cable wears its way through the lining. When you lube a cable & it doesn't seem to help, it could be a consideration.
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post #10 of 22 Old 09-03-2019, 04:21 AM
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Remember the clutch cable inner, on the Wee does not require any lube, only the pivot points require a light coat of grease. The cable is designed with a lube free internal sleeve. Lubing the inner may cause the inner material to become sticky.
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