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Old 06-15-2008, 06:07 PM   #1
loosenoose
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2001 sv650 dead clutch lever. wtf plz halp!

i was doing some experimental poking around in the bike. i'm a newb still after half a year of ownership, and i like to try and understand the mechanical workings of the bike. i took the chain cover off of the front end of the chain and i removed the round diamond shaped part that connects to the clutch lever. when i was putting it back together, i noticed that the clutch lever was very loose feeling. i assumed this was because i had just taken it all apart and the bike possibly just needed to be started for it to tighten up... i dunno...
that didnt fix it. the bike starts, but when i shift into first, the bike dies. im pretty certain that i have everything put together correctly.

while i had the swivel part taken off, i cleaned the bearings and the swiveling stuff with wd40. the pin or axle that the swiveling assembly connects to felt loose so i pulled that out and cleaned it while i had it out. there was a small pool of fluid on the floor when i removed this pin. the pool was approximately wallet sized.

does anyone know what i have done? i dont know the names for any of this stuff, i know that would help, but i think i have been descriptive enough.

if anyone can get a picture of a first gen with the front chain cover removed, that would probably help a lot.i hope i just have something mounted in the wrong direction.
thanks.

my phone number is 936-524-3873 if you can help me out, please give me a call. i kinda need to get back home, lol.
or just respond, i'll probably be checking back to this post in a little while.

Last edited by loosenoose; 06-15-2008 at 06:09 PM. Reason: additional info
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Old 06-15-2008, 06:11 PM   #2
Patrick
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Sounds like you may have the clutch push rod actuator either improperly indexed when you put it back in with the bearings or you don't have it or the pushrod installed properly.

Where are you located at?
If you're not too far from the shop, bring the actuator in on Tuesday and I'll look at it and if it's not right I'll index it properly for you, no charge.
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Old 06-15-2008, 06:28 PM   #3
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thanks dude
i'll go check it out and see if i can get any progress.

i live pretty far from your your shop, but dude, i appreciate the offer. thats awesome!
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Old 06-15-2008, 06:49 PM   #4
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i played around with the parts and flipped the rod over. i noticed i had it in backwards, so after trying the screw part one time i got it working. sweet.

thanks dude.
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Old 06-15-2008, 06:54 PM   #5
Patrick
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Make sure you don't under or over adjust the clutch rod freeplay.
Loosen the 10mm nut, lightly turn in the screw adjustment till it just contacts the pushrod, than back it out a 1/4 turn and tighten the lock nut.

Adjust your clutch cable freeplay to where you have 3/16" of play between the lever and the perch, you should be good to go.
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Old 06-15-2008, 07:10 PM   #6
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And invest in a service manual or download a PDF version. They are invaluable.
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Old 06-15-2008, 09:42 PM   #7
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i didnt mess with the screw on the screw/lever assembly. it just fell out as i was taking the lot apart.
but thanks

and yeah, i have the pdf's here at my house, but i was at my parent's and didnt have them and their internet is slooooow. i didnt want to download them from sv650.org
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