I changed chain & sprockets, clutch no worky - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 17 Old 08-03-2009, 02:19 PM Thread Starter
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I changed chain & sprockets, clutch no worky

Hi All,

The short version: 2004 WeeStrom, 30,000 miles. I replaced the chain & sprockets with OEM, and now my clutch does not disengage. She worked great before I took her apart, so I buggered something.

While cleaning the gunk out, I did remove the clutch actuator rod and cleaned it.

I adjusted the clutch as per the manual, and I can see & feel the clutch actuator rod moving in and out. I ran the clutch adjustment center screw in much farther than the manual says, took all play out of the clutch cable, and the clutch will still not disengage. (I'm judging that by trying to turn the rear wheel with the clutch pulled in. It will not turn if in gear. When the engine is running, the rear wheel will not slow if the clutch lever is pulled.)

Are there any little parts in there I might have lost or assembled wrong? It looks OK according to the service manual, but still no worky. Maybe my clutch, which worked great before, magically picked this time to die?

I read thru all the posts I could find, and didn't find anything I have not already tried.

Thanks!

Blue Wee K4, K1100 w/ Ural hack, 2013 Glee (hers)
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post #2 of 17 Old 08-03-2009, 02:28 PM
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Quote:
Originally Posted by ChuckS View Post
I ran the clutch adjustment center screw in much farther than the manual says...
This statement doesn't make sense to me. The manual says to turn the screw in all the way until it stops, then back out 1/4 turn. How could you turn it in more than all the way?

I would try adjusting it again.

- Gary

Be Ashamed to Die Until You Have Won Some Victory for Humanity. ~Horace Mann

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post #3 of 17 Old 08-03-2009, 10:47 PM Thread Starter
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When I turn the screw, I can feel it contacting the pushrod, but it will turn in until flush with the surface without much effort. No room for the locking nut if the center screw is all the way in.

In a fit of madness, I started her up. The first time I let out the clutch with the engine running, a deep, throaty ----CLUNCK----- came from the gear box. After that, things seemed to work as expected. Out of adjustment, but that was easily fixed. She now seems fine, but is awaiting a test ride.

I can't imagine where the clunk came from.

Also, maybe the manual should say "turn in the screw until contact is made"? Does this screw actually stop on other WeeStroms?

Thanks!

ChuckS

Blue Wee K4, K1100 w/ Ural hack, 2013 Glee (hers)
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post #4 of 17 Old 08-03-2009, 10:57 PM
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Until contact is made might be better terminology. If you think about how the mechanism works, stops makes sense too if you aren't using enough force to push the rod against the spring.

Pat- 2007 DL650A was ridden to all 48 contiguous states. I didn't quite make it to 17,000 miles on the 2012 DL650A.
Nicknames I use to lessen typing, Vee = 2002-2012 DL1000s. Vee2=2014-2016 DL1000s. Wee = 2004-2011 DL650s. Glee = 2012-2016 DL650s
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Last edited by greywolf; 08-03-2009 at 10:59 PM.
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post #5 of 17 Old 08-08-2009, 10:27 PM
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Hey Chuck,

Since you were so kind letting me test ride your '04 Strom before I bought mine, I'd be happy to help you fix this problem. I just had my clutch linkage apart because I did chain and sprockets too....

Let me know if you got it fixed. If not I will help you out.

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post #6 of 17 Old 06-03-2010, 02:22 PM
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I know this post is old, but I'm having the same problem. Can anyone help me out?
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post #7 of 17 Old 06-03-2010, 10:05 PM
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no one has had this problem?

I've assembled it exactly like the photo...........

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post #8 of 17 Old 06-03-2010, 10:49 PM
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Did you adjust the clutch screw and locknut? Did it come apart after you took it off? The usual problems are putting it back in a different position or screwing it in too far. Stop when encountering contact with the push rod. It screw can be turned farther because it will push the rod in. Don't do that. Stop at first contact and back off 1/4 turn so the rod is free even when hot and expanded a bit.

Pat- 2007 DL650A was ridden to all 48 contiguous states. I didn't quite make it to 17,000 miles on the 2012 DL650A.
Nicknames I use to lessen typing, Vee = 2002-2012 DL1000s. Vee2=2014-2016 DL1000s. Wee = 2004-2011 DL650s. Glee = 2012-2016 DL650s
See https://www.stromtrooper.com/general-...nicknames.html

Please vote in the poll on what Strom(s) you have at https://www.stromtrooper.com/informat...-you-have.html
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post #9 of 17 Old 06-03-2010, 11:56 PM
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Almost guaranteed that you put the clutch release assembly back together slightly different. Probably 90 degrees turned one way or another. I did exactly the same thing the first time I changed the front sprocket.

..Tom

2006 DL650: 202,000 km 125,500 miles, Sold
2012 DL650 139,500+ km, 86,700+ miles. Sold
2015 DL1000 New July 2015 195,000+ km, 121,000 miles.

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post #10 of 17 Old 06-04-2010, 10:05 AM
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Quote:
Originally Posted by greywolf View Post
Did you adjust the clutch screw and locknut? Did it come apart after you took it off? The usual problems are putting it back in a different position or screwing it in too far. Stop when encountering contact with the push rod. It screw can be turned farther because it will push the rod in. Don't do that. Stop at first contact and back off 1/4 turn so the rod is free even when hot and expanded a bit.
I've tried all sorts of adjustments on it......turn it ever so slowly until it grabs, and then turn it back 1/4 turn, and lock the nut down..... nothing.

does everyone else's mechanisms look like this?
Attached Images
File Type: jpg clutch mechanism.jpg (37.9 KB, 39 views)
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