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SV650 Clutch issue

  1. #1
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    SV650 Clutch issue

    Having a very strange issue with my clutch and was referred here as many of you owned/worked on/or raced on the SV platform. When pulling in the clutch lever, the bike still feels to be in hanging in gear; it is very difficult to push the bike around the garage while it is "in gear". The bike moves as expected when neutral is selected, but, all other gears it has the same symptom. Clutch cable is in good shape and adjusted properly, worm gear plunger has been disassembled, re-greased and adjusted (in good working order). Pin to the clutch case is clean and free of debris and moves as expected when pulling the clutch lever.

    So I took apart the clutch yesterday and found some black spots on a few of the steel discs, not blue at all, just black (see picture). All of the fiber plates seem to be in good shape, but, I am very new to this, and it is my first motorcycle clutch job, any info or thoughts on the issue would be greatly appreciated!

    thanks,
    jp


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  2. #2
    Super Moderator OreoGaborio's Avatar
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    Re: SV650 Clutch issue

    That looks like a hot spot...

    Are all the steels flat or are any of them warped?

    Got a micrometer? any of em have thickness variations?

    Bet the problem would prob go away with a new clutch pack.

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  3. #3
    Angry Gumball RandyO's Avatar
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    Re: SV650 Clutch issue

    warping from clutching up wheelies, I agree with Oreo

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  4. #4
    Lifer isaac_'s Avatar
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    Re: SV650 Clutch issue

    Quote Originally Posted by OreoGaborio View Post
    That looks like a hot spot...

    Are all the steels flat or are any of them warped?

    Got a micrometer? any of em have thickness variations?

    Bet the problem would prob go away with a new clutch pack.
    Doesn't it concern you the spot is only one place? Wouldn't you expect spots in a sinoid pattern? Could there be an issue with the springs (highly unlikely)?

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  5. #5
    Super Moderator OreoGaborio's Avatar
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    Re: SV650 Clutch issue

    Quote Originally Posted by RandyO View Post
    warping from clutching up wheelies, I agree with Oreo
    If you think clutching up wheelies on an SV warps steels then technically we agree to disagree.

    I'd wager that my race starts beat up a clutch a lot more than my clutching up wheelies.

    Quote Originally Posted by isaac_ View Post
    Doesn't it concern you the spot is only one place? Wouldn't you expect spots in a sinoid pattern? Could there be an issue with the springs (highly unlikely)?
    The bluing in one spot is why I'm wondering if it's warped, bent or out-of-spec steels, mostly because I can't think of any other reason off the top of my head that would cause that.

    Springs..... maybe?

    What does the clutch basket look like? Can't imagine that's the culprit but it's a question worth asking.

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    Last edited by OreoGaborio; 03-22-21 at 07:47 PM.
    -Pete LRRS/CCS #81 - ECK Racing, TonysTrackDays
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  6. #6
    Backwoods lobster boy number9's Avatar
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    Re: SV650 Clutch issue

    You can use a piece of glass or a tile to check for flatness.

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  7. #7
    Angry Gumball RandyO's Avatar
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    Re: SV650 Clutch issue

    Quote Originally Posted by OreoGaborio View Post
    If you think clutching up wheelies on an SV warps steels then technically we agree to disagree.

    I'd wager that my race starts beat up a clutch a lot more than my clutching up wheelies.



    The bluing in one spot is why I'm wondering if it's warped, bent or out-of-spec steels, mostly because I can't think of any other reason off the top of my head that would cause that.

    Springs..... maybe?

    What does the clutch basket look like? Can't imagine that's the culprit but it's a question worth asking.
    something is making the clutch pac drag, worn clutch would tend to slip instead, warping, what ever the cause, no, I don't really think wheelies caused it

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  8. #8
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    Re: SV650 Clutch issue

    I checked them all with a micrometer and they were all within thickness spec. The plates appeared to be flat, checking them against something flat is a good idea...a little more calibrated than....my eyeball.

    All of the springs were between 1.99"-2.04" so I would assume that those are okay.

    Thanks for the info everyone, will keep updated if solved.

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  9. #9
    Backwoods lobster boy number9's Avatar
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    Re: SV650 Clutch issue

    Quote Originally Posted by jp View Post
    I checked them all with a micrometer and they were all within thickness spec. The plates appeared to be flat, checking them against something flat is a good idea...a little more calibrated than....my eyeball.

    All of the springs were between 1.99"-2.04" so I would assume that those are okay.

    Thanks for the info everyone, will keep updated if solved.
    What about the clutch basket? If the "fingers" on the side have grooves or ridges, they will stop the steels & frictions moving in and out.


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  10. #10
    Soul Rider Paul_E_D's Avatar
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    Re: SV650 Clutch issue

    That plate looks fine. My guess is the odd adjuster that bolts to the cases is out. It's a tricky bugger to set up sometimes. I had issues with it when I put a slipper clutch in.

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  11. #11
    Senior Member Mgiossi's Avatar
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    Re: SV650 Clutch issue

    Out of adjustment is my guess. Not at the lever. You need to adjust the clutch down at the push rod.

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  12. #12
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    Re: SV650 Clutch issue

    Update time. number9 I think you were on to something. The basket and the carrier both are a bit grooved, see pictures. I'm guessing its time to replace these? Or is this normal wear? I put the whole thing back together with new plates, fibers, and spacer washers (before realizing that the grooves were indeed there) and had the same symptoms...took it back apart, and well here we are. Any thoughts by people smarter than I am on this subject?

    SV650 Clutch issue-h8ecowm-jpg

    SV650 Clutch issue-qjlt36m-jpg

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  13. #13
    Soul Rider Paul_E_D's Avatar
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    Re: SV650 Clutch issue

    That's normal and not the cause of the issue. It is most certainly out of adjustment at the plunger.

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    Paul_E_D


  14. #14
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    Re: SV650 Clutch issue

    Bike is all fixed and running. Thanks for the help everyone. The clutch release mechanism was the issue, it was missing bearings inside that I initially didn't notice. Bought a new one, bolted it on, and the problem disappeared magically. Appreciate all of the ideas and input.

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  15. #15
    Super Moderator OreoGaborio's Avatar
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    Re: SV650 Clutch issue

    Awesome. Glad you got it sorted!

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