Motorcycle Repair: Clutch problems Suzuki GN125/E, clutch assembly, clutch cable

Question
Hi Mark,
I have a Suzuki GN125/E 1998, I've been having some problems with the clutch recently. The symptoms are as follows:
1.Biting point sometimes does not occur until clutch is entirely released.
2.When that doesn't happen (and the biting point is where it should be) the clutch is sloppy and acceleration is very poor.

Initially I tried tightening the clutch cable but it made no difference. I assume there is a fault with the clutch assembly, but I have not done any work on the engine/gearbox before. I would like to attempt the repairs myself. I've got a few questions, and any pertinent advice would be appreciated.

1. There seem to be many different components that could cause this problem; friction and steel plates; clutch springs and release mech; hub and drum. Can I easily identify/replace the faulty component or would I want an entire clutch assembly?

2. Can these parts be salvaged from old bikes or do I need new parts? (What's their realistic lifespan?)

3. Any specialist tools I'll need?

Thanks,

JonnyD

Answer
Hi Jonny,

I recommend that you obtain and use the Service Manual. You get what you pay for with manuals, spend wisely. Cost is proportionate with quality. Check your local public library for manuals. They have quite a selection at my library and they don't mind the pages being gresasy from fingers.

Try properly adjusting the clutch cable per service manual instructions. If problem persits, remove clutch plates and measure according to service manual. If plates measure within service limits, try shimming each clutch spring with an appropriate sized metal washer. This may restore spring to useful condition and buy some time before replacement.

Your Questions:

1. There seem to be many different components that could cause this problem; friction and steel plates; clutch springs and release mech; hub and drum. Can I easily identify/replace the faulty component or would I want an entire clutch assembly?

Answer:  It's recommended to replace fiber plates, metal plates, and clutch springs together as a set. The hub and drum rarely need replacing.

2. Can these parts be salvaged from old bikes or do I need new parts? (What's their realistic lifespan?)

Answer:  Use new parts only. Old parts are worn. Lifespan depends on riding habits.

3. Any specialist tools I'll need?

Answer:  Shouldn't need any special tools.


Respectfully,
Mark Shively