OzVMX Forum
Marque Remarks => Suzuki => Topic started by: Xedent on December 23, 2014, 02:20:38 pm
-
Hey guys, I have just picked up a 83 model ts185 and I'm having problems with the clutch.
It feels jerky / not smooth to pull so I disconnected the cable and lubed it then put it all back together.
But now it seems that the cable just stretches as every time I use it it loosens.
It is still jerky/not smooth to operate.
I have replaced the oil in the gearbox but didn't help.
Any one have ideas?
Thanks Clayton
-
Possibly the fingers on the clutch basket are badly worn ( Notched )
-
the fibre plates may be falling to bits?
check out a diagram of the clutch and the operating mechanism and make sure yours is all there.
there is a ts forum on the web so you should get plenty of help on that one. google oogle it
-
A new cable that is confirmed as the correct one for your bike is where I'd start before anything else.
Tex
-
worn fingers on the clutch basket for sure.You can remove the basket and file them smooth again to get a bit more life from it but it should be replaced as that allows the fibres to rotate a bit within the basket and they will end up snapping off.
get a new cable while your at it.
for the gearbox use plain old 40 grade non friction modified mineral based oil.. Nothing else.
(http://www.rekluse.com/images/notched_basket.jpg)
see those grooves on the side of the basket fingers?
They shouldnt be thee and grab the fibre plates and stop them from separating smoothly
check you fibre plates too as some fingers may be snapped off already
-
Thanks guys, I'll pull it apart and have a look.
Cheers
-
If your clutch basket looks like that and this is on the bike you just bought and PMd me about Id say it has a teensy bit more than the genuine 850klms on it.
-
Yeah, it still has original tyres?
-
Uhuh. farm bike.
lots and lots of miles in low gears will do that to a clutch basket. hopefully your gearbox isnt worn too badly as that and the clutch is what cops most of the stresses when your on and off the throttle chasing cows.
trials tyres dont wear much puttering around on grassy paddocks.
fingers crossed for you.
-
Yeah sounds like that Pokey, thanks
I have pulled cover off and the basket fingers don't seem worn? Although the outside of them/basket has wear?
(http://i51.photobucket.com/albums/f381/Xedent/Mobile%20Uploads/20141224_083134_zpsaywn2whu.jpg)
(http://i51.photobucket.com/albums/f381/Xedent/Mobile%20Uploads/20141224_083138_zpsqw78402x.jpg)
(http://i51.photobucket.com/albums/f381/Xedent/Mobile%20Uploads/20141224_083612_zpsagcqndce.jpg)
Thanks for the help guys
-
Holy crap. Something has come loose. It will be in there somewhere.. is a little wear on the fingers but have to dissasemble to inspect. Watch those springs n pins they are a bitch the first time u play with them and for the next twenty. A hook and long nose pluers and keep fingers clear and wear eye protection.
-
definitely has ridges an easy fix with a file ;) ..... suspect nut is loose behind pressure plate or wrong thickness plates ??
-
Pulled the clutch plates out today, there are little marks/ grooves defiantly not as bad as the picture pokey uploaded.
The basket seems to have play but middle doesn't? Don't think it did when plates and springs were I'm it.
I need to find a basket tool to hold it to undo the nut.
Also found the rear sub frame has taken a hit, would it be hard to bring it back to centre?
(http://i51.photobucket.com/albums/f381/Xedent/Mobile%20Uploads/20141226_160004_zpswmbe9hmu.jpg)
(http://i51.photobucket.com/albums/f381/Xedent/Mobile%20Uploads/20141226_155953_zpsunxx1hly.jpg)
Cheers
-
There are basket tools on fleabay But ive never bought one.
weld a handle onto a spare steel clutch plate.. voila
as for the frame. yeahh.. good luck with that. maybe find a heating torch before you pull it back into shape. Also check for cracks or grind and reweld them after its straight. they are just a mild steel frame so working on them wont be too hard.
-
should have no trouble finding a good frame if that one is bent severely...
-
Straitened the frame today and also got the basket off and filed it, is the basket and gear supposed to have play in the rivits holding them together?
(http://i51.photobucket.com/albums/f381/Xedent/Mobile%20Uploads/20141227_162622_zpsqsoi8lx7.jpg)
Also how does the filter supposed to seal in the air box? It moves around in there. Guessing I'm missing parts?
(http://i51.photobucket.com/albums/f381/Xedent/Mobile%20Uploads/20141227_165550_zpss4yxbgkp.jpg)
Thanks
-
You should find that the side cover on the airfilter housing holds it all together. those foam bits look as loved as old mabel whos been sitting at the end of the bar for the last 50 years. id replace that before it powders and gets sucked in to the carb. It wont be sealing much in that condition. FRI jin the street behind Wises rd will have some foam to do the job
the clutch basket will move a little of the rivets but not much. if its very loose something is wrong and it needs replacing..bit bigger of a job.. i would still like to know what scored the outside of the basket.
-
Thanks alot for the reply, it didn't have much play in the rivits though it does move a little.
Yeah whatever scored the basket i think has been removed as the side cover had been taken off previously.
With the air filter is there foam or rubber that goes between the circle part / outlet of filter to seal on the inside of air box before goes into carb ?
Seems like there's a glue around the outlet circle inside air box that a seal / foam might have preciously been?
Cheers
-
in your pic . underneath the top right hand corner looks like a guilty part
-
Thanks, ok I'll get some new foam for front and back.
Is another piece supposed to go here between box and filter? As there's nothing stopping dirt going past from over top or under.
(http://i51.photobucket.com/albums/f381/Xedent/Mobile%20Uploads/20141227_203405_zpsjksfa52z.jpg)
-
Originally there was a rubber triangle shaped gasket (about 3mm thick) on the back of the airbox (side where centre stud is attached to) and there would have been a gasket on the inlet side too as you can see the remains of the glue in your photo. I cant remember if this one is rubber or foam though. On mine what i did was glue a foam ring onto the front of the actual air filter cage. I also run it with the snorkel removed from the airbox too.
It looks like you are missing a steel part with a rubber gaket on it which goes over the stud and helps locate the cage in the airbox.
Part 5 and 6 here
http://www.alpha-sports.com/suzuki_parts.htm?fpg=/dspt/1980%20TS185/01.htm
(http://www.alpha-sports.com/dspt/1980%20TS185/01.gif)
I have now just remembered, i think i made a fresh seal for the triangle rubber shaped seal from this stuff
http://www.pcracingusa.com/ProSeal-PC10X-Universal_p_61.html
you can find these universal kits on ebay etc and is actually ment for airbox/filter cage seals.
-
Thanks alot LWC82PE, any chance you have the parts 5 and 6 I'm missing so I can get some measurements, hopefully make something work.
Thanks Clayton
-
I bought a spare airbox a while back to get another side lid. I am not sure if it came with those parts though but i will have a look tomorrow. They would be available new from a dealer though.
-
I just checked and i am sorry to say i do not have any spares of these 2 parts. I can tell you the rubber gasket at the back of the airbox is more like 4mm thick though.
-
Thanks for that, i just got some rubber and making it all now, just another question, I purchased a new filter element a uni filter one.
Do you oil these with filter oil?
Cheers
-
Yes
-
I fixed the clutch basket and clutch yesterday which I changed the oil etc
I took for a ride after which went well.
But today while figuring out the electrics the kick start went funny as it only grabs every now and then.
Also now you have to use your hand to get it from 1st/second and it really clunks?
I did notice when riding yesterday that when going down gear/selecting first when it was in first it had a funny light grinding noise that didn't seem normal.
Any ideas?