Motorcycle Repair: first time clutch problems, clutch assembly, clutch cable

Question
Hi Chris,
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.
 Well, to start with, the clutch should engage near the beginning and disengage near the end of lever movement.

 The parts you need must be purchased new.  The clutch basket itself does not tend to go bad.  Certainly not in a 6 year old bike.  The clutch plates and springs shouldn't be bad either unless the bike has been ridden exceptionally hard (as in street racing and other squidly, hot dogging activities) and/or the clutch has been misadjusted from the begining.

 Some bikes have a secondary adjustment to the clutch.  The cable adjustment is at the lever, but the secondary adjustment for the clutch itself is located either at the engine side of the clutch cable or on the engine case (it will look like a BIG recessed standard screw).
 Start with that adjustment after you reset the clutch cable properly.

 If that doesn't do the trick, then clutchplates and (possibly) springs are in order.  For changing that, you will need a clutch holding tool.  That tool holds the clutch basket in place while you loosen and tighten the clutch bolts.  You can do it without that tool, but it will require a bit of improvisation and will be far more difficult.  You will also need a torque wrench.  If the bolts are not torqued correctly, the clutch can come apart on you with catastrophic results.

 As far as lifespan of the clutchplates and springs, the manuafacturers will give you a specific miles range that the clutch assembly will last for, but that is only an average.  I have seen clutch assemblies last as long as 20 years and as short as 3 years.  It all depends on how hard you ride the bike.

Good luck.
FALCON