Broken Clutch?

I

imnothng

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Bike- 2004 DRZ 400S

So I'm pretty inexperienced but I wanted to try doing a simple thing like replacing my clutch cable. I installed the new cable the same way as the old one. Here is the problem I ran into. When I squeezed the lever there was resistance and the cam shaft pin and the clutch arm on the top of the engine moved back and forth. Then after squeezing it a couple of times I felt something "let go" and then there's no resistance. The cam shaft pin and clutch arm still move back and forth, but it's like it's not attached to anything.

I started the bike and shifted it down while squeezing the clutch and it's definitely not working. I have no problem trying to fix it myself, but I'm afraid even if I open up the clutch I have no idea what I'm looking at, so I'm not sure if I will be able to see what's broke. I was thinking about taking it in to a shop, but I would rather learn this myself.

If there's any ideas you guys have, or could just point me in the right direction I would really appreciate.

Thanks.
 
Lay the bike on its side and open the clutch cover (prevents you from losing oil)
pull in the clutch and see if the plate is moving. Off not, take it off and pull out the discs and fibers... Put them in order so they go back in the same order. Pull the clutch again and see if the rod is moving properly.

Ive had the clutch stick together after winter storage. Thought something was seriously wrong but I just had to ride it and give it some harsh launches to get it to break free. This caused a loose lever.

Just some ideas... Mx bikes are simple and good to learn on!
 
Is your clutch engaged or disengaged presently? In other words will it roll freely in gear?

Look at the exploded view of clutch release mechanism on BikeBandit OEM parts fiche. It's very simple.
 
BNKN said:
Is your clutch engaged or disengaged presently? In other words will it roll freely in gear?

Look at the exploded view of clutch release mechanism on BikeBandit OEM parts fiche. It's very simple.
Click to expand...

It is disengaged, it will run when I shift it.
 
rmemedic said:
Lay the bike on its side and open the clutch cover (prevents you from losing oil)
pull in the clutch and see if the plate is moving. Off not, take it off and pull out the discs and fibers... Put them in order so they go back in the same order. Pull the clutch again and see if the rod is moving properly.

Ive had the clutch stick together after winter storage. Thought something was seriously wrong but I just had to ride it and give it some harsh launches to get it to break free. This caused a loose lever.

Just some ideas... Mx bikes are simple and good to learn on!
Click to expand...

Thanks, I will be taking a look at it on the weekend. There's just something that freaks me out about laying a bike on its side, even though I've done plenty of it by mistake, lol.

I really want to figure it out on my own, but if I can't get it fixed this weekend I think I'll have to take it in to a shop.
 
imnothng said:
It is disengaged, it will run when I shift it.
Click to expand...

Because this happened immediately after the cable change I doubt the problem is internal. I suspect you took the lever arm off to make it easier to install the cable and didn't get it back on in the correct position.
 
BNKN said:
Because this happened immediately after the cable change I doubt the problem is internal. I suspect you took the lever arm off to make it easier to install the cable and didn't get it back on in the correct position.
Click to expand...

Nope, I started to but then realized that there was enough play to not have to.
 
imnothng said:
I have no problem trying to fix it myself, but I'm afraid even if I open up the clutch I have no idea what I'm looking at, so I'm not sure if I will be able to see what's broke.
Click to expand...

imnothng said:
Nope, I started to but then realized that there was enough play to not have to.
Click to expand...

Perfect. Then it's internal. I checked the parts fiche and your setup looks exactly like my sons' DR650 which I've been into. The clutch and release mechanism is simplicity itself. Search the net for tutorials. Follow good practices of keeping everything in order as it comes apart. Your biggest challenge might be the clutch cover gasket, no kidding. Have a new one handy.

Gut check time:p
 
I'm at a loss. I just had it all apart minus the basket because I couldn't get the hub nut off. I didn't want to take my usual approach and keep going at until I broke or it broke, so I'm throwing in the towel.

I did notice something though. When I turn the clutch release camshaft it moved the push piece out. So I put it all back together hoping in all hopes that it fixed itself (hahaha, I know, I know) but alas, there's still no resistance.

But as far as the gasket goes, I may sound like a total noob (of which I kind of am) but it was like an o ring gasket. Aren't those reusable? I've only ever replaced a head gasket on a car and that was that flat paper kind of thing.
 
On the clutch cover is a vertical shaft that goes down and engages the puller that pulls the pressure plate out. When you turn that shaft, it should not be "pushing" the pressure plate, it should be "pulling". It can be a bit tricky to get that shaft to engage the puller properly, and it happens in the process of installing the clutch cover, so you can't see what is happening, either - you have to feel it.
 
imnothng said:
But as far as the gasket goes, I may sound like a total noob (of which I kind of am) but it was like an o ring gasket. Aren't those reusable? I've only ever replaced a head gasket on a car and that was that flat paper kind of thing.
Click to expand...

Pardon me, I've only ever seen the paper kind on clutch cover. That's great that Suzuki chose to go with the O ring, much better. I think "technically" you're supposed to replace those O rings every time but it's not that critical. The DR650 has O ring on filter cover and my son has never replaced it after many oil changes altho he has a new one on standby just in case. Take that for what it's worth.
 
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