clutch problem

heidi360deg20... · L Plate Warrior Joined: 09 Dec 2003 Karma :

Hey a buddy of mine has a 97 suzuki katana 600cc bike and he is having clutch problems, its real stiff to ingage and it is getting harder. he has replaced the cable and everything else but not the clutch it's self. he dosnt know much about it but i was wandering could it be hydrolic , and if so how much dot 3 should he put in? and what else should he do? any adjustments?
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MarJay · But it's British! Joined: 15 Sep 2003 Karma :

If it has a cable (which I think the GSX600F as its called over here has) Then its not hydraulic. Apart from that I can't help. Sorry Smile

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Remember kids, bikes aren't like lego. You can't easily take a part from one bike and then fit it to another.

Sparks! · Sir Tart-a-lot Joined: 30 Aug 2003 Karma :

Erm, if you've replaced the cable, and assuming you have adjusted it appropriately then it's only really going to lead to the clutch plates/springs.

It's a very easy job to replace them and shouldn't take you much longer than an hour really.

All you need to do is, drain the oil out. Undo the clutch cover casings and you'll see the clutch assembly.

There will be around 4/5 possibly 6 bolts that you'll see on the clutch basket bit, undo these in a star sort of sequence, DON'T undo them one at a time, they hold in the clutch springs and so by undoing them bit by bit in a star pattern you won't do the clutch any damage and the springs won't pop out etc.

Once the springs are off take the center bit out and replace the friction plates then rebuild using new springs. Making sure everything goes back where you put it Wink

Then check the clutch adjustment and see if it's any better.

You can't "really" put the clutch back together incorrectly without noticing... just make sure you remember how everything went in. And take note of the clutch push rod make sure it fits back in correctly.
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Ste · Not Work Safe Joined: 01 Sep 2002 Karma :

Sparks! · Sir Tart-a-lot Joined: 30 Aug 2003 Karma :

hehe speaking from experience? lol
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Ste · Not Work Safe Joined: 01 Sep 2002 Karma :

Nope. I just got to watch as Luke tried to put it back together Smile

Sparks! · Sir Tart-a-lot Joined: 30 Aug 2003 Karma :

Don't tell me Laughing

, he had trouble getting the plates and corks lined up and fitting into the basket properly??
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Kickstart · The Oracle Joined: 04 Feb 2002 Karma :

Hi

Also worth checking the thrust bearing in the clutch. This turned out to be shot on my XJ600 when I bought it. Only about £5 for the bearing and easy to fit.

On the XJ the gearchange became nasty and if you put the bike on the centre stand and ran the engine in gear so the back wheel was spinning, pulling the cluch meant the back wheel stopped almost instantly. Putting it in neutral and spinning the back wheel by hand and it would spin freely.

All the best

Keith
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