Strange Clutch Action

[lrenaud]

I bought a 2001 Suzuki Marauder (800) for my wife and have ridden it a couple of times lately trying to burn a bit of carbon out of the carbs and get it running better for her. The previous owner was a lady who put 5k miles on the bike in 3 1/2 years, didn't do much in the way of maintenance, and didn't know how or bother with any adjustments that I can tell.

The clutch seems to work fine in gears 1 thru 4 but in 5th gear at about 60 mph when I hit the throttle the clutch pulls slightly on my hand and when I let off the throttle it releases back. I've never had that happen before. Can't seem to adjust it away - all the way doesn't help - all the way in doesn't help either.

Has the clutch just been worn out on this thing ?? Is there a spring in the clutch that might need replacing?

Either way, I'm probably stuck taking it to Suzuki for work and will have to pay whatever it costs - just thought I'd ask for input here.

BTW, it never fails, the lady had a 4 year extended warranty on the bike BUT Suzuki wants the paperwork she was given in order to transfer it and of course, she doesn't have it. :twisted:

[kurt]

Clutch plates are cheap and easy to install. I'd start there.

[pinecone]

Is the cable in good shape? Is it lubed properly? Is there a kink in it somewhere? Bear in mind I can't see the bike or ride it. Silly problems like that are usually best diagnosed in person.

Before I would go tearing into a clutch basket, I would disconnect the cable from the clutch arm on the motor. Work the cable. If it binds with no clutch to work, get another cable. If not, you may have a problem with plates hanging up in the basket.

To me unless the bike was beat to heck, a clutch should not be worn out unless the previous owner "rode the clutch". She only rode the thing 1500 miles a year. That is low miles even for a bike.

Good luck. :-)

[lrenaud]

Yeah, that's where my confusion comes in. She'd have had to ridden the bike with the clutch half way in/out for the entire 5k miles to wear it out so quickly but as far as I can tell there is nothing else wrong here.

Btw, I forgot to mention that the outside of the clutch basket gets VERY hot when riding the bike.

[kurt]

Btw, I forgot to mention that the outside of the clutch basket gets VERY hot when riding the bike.

Sounds like you may need fiber plates and metal ones.

[pinecone]

Yeah, that's where my confusion comes in. She'd have had to ridden the bike with the clutch half way in/out for the entire 5k miles to wear it out so quickly but as far as I can tell there is nothing else wrong here.

Btw, I forgot to mention that the outside of the clutch basket gets VERY hot when riding the bike.

Something is keeping the clutch engaged when it isn't supposed to. That's why I rec'd the cable check first. Are you planning on replacing the clutch yourself?

[Tx Rider]

Sounds like a cable adjustment. There is usually adjustment at both ends, and on some engines adjustment of linkage rods inside.

What do you mean by pulling on your hand? Is this with the clutch lever pulled in and revving the motor? or just riding along with the clutch released and your finger just riding on the lever?

If it's moving the clutch lever when released and just riding along it sounds like the clutch cable isn't adjusted, the lever, cable, whatever should be fully disengaged.

You might also want to check the motor mounts, or how the motor is mouted. If it's rubber mouted and the engine can move, it could be normal.

Worn our clutches usually slip, like you slip the clutch to take off. It would be like riding while pulling the lever in half way all the time.

Sounds like it's either too tight and something needs to get loosened, or it's a normal thing.

[lrenaud]

Some good ideas on things to check.

The clutch action occurs while riding in 5th gear with the clutch fully out but my hand resting on it - when applying throttle, the clutch draws out against my hand. Releasing the throttle causes it to go back to it's previous resting position.

I can't hear any slippage while this is happening but it might be doing it.

This doesn't happen in lower gears - only in 5th gear at higher speeds.

Well, at least that's the only time I've noticed it so far - we haven't had the bike that long and I've only ridden it a couple of times. My son in law noticed the same thing though and we've been trying to figure this thing out.

[Tx Rider]

I would bet it's not adjusted right, or the engine is moving and taking slack out of the cable. Check how the engine is mounted, if rubber mounted or loose.

Check the cable ends and look at both ends connection and adjustment.

You might even try holding the front brake and letting out the clutch while sitting to see if the engine moves at all.

I'm not familiar with that engine, but I know some older styles use a rod that goes through the engine, sometimes the center of the clutch housing itself that can be adjusted. The cable just moves a lever to depress the rod inside.

Somewhere between the clutch basket and the handlebar lever something is changing when you hit the gas that's taking slack out of it somewhere.

Of course getting a service manual so you can get the proper look at all the parts and the proper adjustment routine might be the best bet, and then you have it for reference for other maintenance jobs.