2001 Suzuki SV 650 S Logo
Posted on Apr 29, 2011
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The clutch cable is seized so i'm going to replace it, tried to operate the lever down at the gear box manually to check the drive, "very tight" is this normal? obviuosly thats why you need a lever or does this indicate a problem with the push rod or clutch assembly

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gavin jones

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  • Suzuki Master 1,508 Answers
  • Posted on Apr 29, 2011
gavin jones
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Joined: Apr 04, 2010
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It will feel tight at the bottom, the clutch lever probably gives something like a 10-1 leverage.
You may be able to move the bottom lever with a small pipe or spanner attached , but I would suggest wait for the new cable.

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If belt is ok, then likely the rear wheel dogs have seized. Review the following PartsTree diagram, what they call ratchet key item 3.
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1991 Prizm. When I release clutch in first, why doesn't it go?

1991 Prizm (aka, Corolla) dead clutch (aka SLIPS)
does engine crank and start in gear? in gear?
the first thing to check is the clutch pedal actuation system.
cable on some , and Hydraulic on othere
open hood, see that MC for clutch, is the Reservoir dry?
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yes, then the slave or mc is bad or both, the one leaking is bad.
Most cases Hydra clutches can not cause slip. (rare)
its a cable, can if cable frays inside or rust, (big time common)
well all cable clutches need service, if not it fails.
called setting free play in the book, FSM book
I love the above post where he guesses then sets a price.
first is diagnosis prices last and varies all over planet earth
and is useless here. prices. always.
Ill look in Michell's for you.
it's not a cable system,
Mitchells shows, hydra. clutch
so unbolt the slave.(on bell)
start car in gear, does car move. yes /no?
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i posted both ways, as these era cars run to clutch systems.
that could even change mid year, production.

S= slave
Bell = bell housing
L = clutch lever.
see the 2 bolts?
some Slaves can seize (due to running old fluid full of water)
Dot3 fluid is hydrascopic and needs service every 2 years. min.
26082435-4gmiw4kjhjrck3uewcae1lzo-4-0.jpg we check the MC and all parts related here.
to see if the L lever is stuck to the right above.
never condemn any clutch until these checks are done
or go broke fast. IMO
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How do you replace the clutch on a 1969 morris minor?

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Seized gear box.

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When i start to drive in first gear, i experience extreme shaking

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I was releasing my clutch and heard and FELT a "snap." It's a 1993 Geo Metro with a 3 cylinder engine and manual transmission. After the snap it felt like it wasn't quite "grabbing" when I released the...

Try a new cable, and make sure the funky suzuki weak pedal
is not cracked or the spline at top end is not stripped.
there are 2 parts here. not counting the shift lever that can fail.
1: the pedal actuator and cable.
2: the clutch actual.

if the clutch lever moves (at bell) 1 inch the (no play) then the clutch is bad.
see that simple test? the 1 inch?
you step on the pedal and the lever on the throw out moves 1inch.
that is all the curator does.


the cables is only good for like 100kmiles, (more if lubed)
and like to break in the center where you cant see, they fry there
and prevents you from setting up free play right.
see the problem here? if the cable is bad , you had tension on the
bell lever and the clutch slipped and burned up.
the cable is the cheapest part and the lowest labor.
why folks replace it last , is a wonder. but see that all the time.

do you understand the free play rules here. on all clutches.
(cable or lever type)
it must have free play, 1/2 inch at the pedal or 1/8" at bell lever.
if not the throwout burns up.
if not, (worse) the clutch slips.
if not the PP fingers overheat and the spring fails, (anneals)
free play.
and changes to tighter as you drive and clutch wears.
if you cant get the free play right ,its a big issue.
the #1 reason is bad CABLE. $25 and its out.
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1. replace your gear oil.
2. is this an automatic or manual transmission engine? if manual, adjust your clutch release a little higher than usual to let your clutch engange earlier.
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Clutch seems to be seized because bike has been sitting for years

Is the clutch lever sized or is the plates sized?
Usually the plates inside sizes, all you have to do is select gear 2 or 3 without starting the bike's engine,operate the clutch lever and push the bike,it should release, the rear wheel should now rotate freely with clutch lever in operation and in gear.
Hope this helps!
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