Suzuki 2 Strokes

What's wrong here? According to the manual, the arm should be aligned with the casting arrow in the relaxed condition. Instead, it is like this. And yes, the arm is correctly keyed to the actuator. If I remember correctly, the 3 roller piece inside is symmetrical. No way to get it out of whack. It seems to operate the clutch OK where it's at -- but it's wrong. What am I not doing right?

Once you have the cable on it, it will be roughly at the right angle. Right now, its hanging slackly.
If you haven't dismantled it to clean and lube / pack with grease, its really worth it for a smooth lever (did it on mine last year and its smooth as butter now).
Cheers,
Mike

I had it apart, cleaned it up and re-greased it. According to the book, I need to remove the 3 big screws and rotate the plate to correct the arm location. Cable adjust won't do it as the clutch begins engagement just a few degrees from where it's at in the photo. I must have got it out of index when I put it back together. Fortunate for me, I did not lok-tite the screws. Back at ti!

Hi Coyote,

the plate can be mounted in 3 positions. The actuator can be mounted in the plate in 4 positions if I remember that right. So you have to use another combination. This means, turn the actuator out , turn it 1/4th rotation and remount it in the plate. Then turn the plate 120° and try again. Repeat this until it fits.

Regards
Dirk

I fixed it, but I don't know how. I didn't disassemble anything. I found there is a fine line between having the clutch adjusted and having the arm remain at the arrow when relaxed. Well, that's where it is now Adjusted the clutch till I felt resistance, backed it off i/2 turn and locked it down. Stops right on the arrow and there is about 1/4" play counter clockwise before the push rods contact the push piece.