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Clutch Trouble Suzuki Across

Discussion in 'Suzuki 250cc In-line 4's' started by Milt94, Sep 24, 2015.

  1. Milt94

    Milt94 Active Member Premium Member Contributing Member

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    My Bike:
    Had 1997 Suzuki Across, 2014 Ninja 300, 2002 Yamaha XT250, 2007 Suzuki GS500, 2001 Honda CBR600F4i, 1991 Kawasaki GPX250
    So my across has been stationary for far too long but finally making progress.

    I bought the bike 8 weeks ago and it hasn't been reliable from the get go.
    It was always hard to start and kept flooding.

    I replaced the needles and seats as well as put some inline filters between the tank and pump, and pump and carbs.

    I also replaced the choke plungers to help with the cold starts because I learnt that they tend to wear and stick on.

    I also replaced the throttle cable.

    So I have learnt loads from my first bike before being able to ride it.

    So after cleaning the carbys and getting them back on, I bump started the bike to get some fuel running through the system and noticed it was tough to shift the bike to 2nd to do the start.

    I rode around for a bit (in 2nd) to warm it up but found that the clutch was not asissting the gear changing. I could start the bike in neutral but shifting to first to ride away would just cause a stall.

    I have never touched the clutch cable or gearbox and am abit confused.

    Just wondering if anyone has any experience or ideas.

    Thanks in advance.
     
  2. kiffsta

    kiffsta Senior Member

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    How tight is the clutch cable ? You should have 2-3mm of free play at the lever where it goes into the perch
     
  3. Milt94

    Milt94 Active Member Premium Member Contributing Member

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    I think the free play is in that range but ill definitely check to make sure.
    From my reading I have become worried that because it has been sitting for a few weeks that the oil has made the gear plates stick together. Hoping its just the cable
     
  4. Phil

    Phil Senior Member Contributing Member

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    I wouldn't worry about the plates sticking after such a short spell off the road. Had you said a couple of years...I could possibly agree. Sure it will be fine.
     
  5. Milt94

    Milt94 Active Member Premium Member Contributing Member

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    I have the 2-3mm of free play at the lever, should i make any adjustment to the threaded part of the cable where it meets the gearbox?
     
  6. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Loosen the cable completely on the handlebar end, and then adjust the cable on the gearbox end. Then adjust the handlebar end. Check to see if your clutch is then operating properly.
     
  7. Milt94

    Milt94 Active Member Premium Member Contributing Member

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    Had 1997 Suzuki Across, 2014 Ninja 300, 2002 Yamaha XT250, 2007 Suzuki GS500, 2001 Honda CBR600F4i, 1991 Kawasaki GPX250
    Thanks for the advice. All sorted.

    Now just need to sort out idling (idle mixture screw adjustments as far as im aware) then ill be a happy rider.
     
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  8. Milt94

    Milt94 Active Member Premium Member Contributing Member

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    My Bike:
    Had 1997 Suzuki Across, 2014 Ninja 300, 2002 Yamaha XT250, 2007 Suzuki GS500, 2001 Honda CBR600F4i, 1991 Kawasaki GPX250
    Could an incorrect clutch adjustment lead to massive power deficiency throughout the rev band.
    I went for a test ride this afternoon and had no punch at any point in the revs, im thinking that my adjustment of the clutch was the culprit.

    Any ideas?
    Cheers
     

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