Suzuki TF125 - clutch issues

[DeadeyeDent]

Hi Guy's,

First post here so apologies its diving straight in asking for help....

I recently bought a second hand Suzuki TF125 (my first motor bike) purely for hunting access on famr tracks etc. and it went fine the first days i used it on a mates farm then it was parked in my garage for a few weeks till its next use. When i started it on my next outing each time i tried to put in to gear it would stall. I eventually managed to take off and it seemed fine while I was driving and when i tested it at my destination to make sure i would be able to get out the next day.

Unfortunately, when i started it the next day it did the same thing and once getting it driving again it seemed to be fine changing gear up and down smoothly. Got it home and have had a wee go at adjusting it but still cant get it into gear without stalling. I noticed there seemed to be bugger all oil in the trans so have topped this up but still same issues.

I havent been able to find a manual or any details about fixing the clutch on the net so was wondering if anyone here can chip in with some info on how to adjust and/or replace the clutch or point me in the direction of an online manual so i can try and resolve this?

[unstuck]

Gidday, what exactly do you mean by stalling? Sounds more like an idle or mixture problem to me. :Punk:

[DeadeyeDent]

Gidday, what exactly do you mean by stalling? Sounds more like an idle or mixture problem to me.

It idles and runs fine just as soon as I put it into 1st gear with the clutch held in it jumps forward and stalls - exactly the same as if i tried to change into 1st with no clutch if that makes sense?

Noticed this morning it seems to be leaking trans fluid from either the gear lever input or the front cog. Starting to think i bought a dud......

[FJRider]

It idles and runs fine just as soon as I put it into 1st gear with the clutch held in it jumps forward and stalls - exactly the same as if i tried to change into 1st with no clutch if that makes sense?

Noticed this morning it seems to be leaking trans fluid from either the gear lever input or the front cog. Starting to think i bought a dud......

There should be an adjuster at both ends of the clutch cable. If they are at the maximum setting ... the clutch pads are probably buggered.

Not really a major job ... an hour or so tops ... No need to drain the oil. just remove the fuel tank and lay the bike on it's side ... clutch basket side up.

[mossy1200]

If its been sitting a long time the clutch fibres are likely stuck to the plates.
Put bike in first gear and pull clutch in with motor off and rock bike forwards and back and they may come unstuck.
You may need to take the clutch cover off with bike leaning 45deg the opp side and free the plates by hand one at a time with light pressure twisting a screwdriver ( LIGHT PRESSURE ).

[DeadeyeDent]

thanks for the replies guys - FJRider I received your PM and will have a reply inbound shortly

[DeadeyeDent]

bugger...... must need to have a certain number of posts to send a PM as i tried to reply but it said i needed a greater involvement in the site first.

FJRider - if you want to send me a quick e-mail to sean@southernplanning.co.nz i'll get in touch

Cheers

[FJRider]

bugger...... must need to have a certain number of posts to send a PM as i tried to reply but it said i needed a greater involvement in the site first.

FJRider - if you want to send me a quick e-mail to sean@southernplanning.co.nz i'll get in touch

Cheers

done ...............

[DeadeyeDent]

Hey guys, been ages since i posted last. Had a range of other bills and priorities to sort out but have started trying to resolve the issues with this bike. I replaced the seal behind the front cog which stopped the transmission fluid leak.

I bought and received a clutch fibre kit this week and have just drained the oil and taken the transmission cover off to get at the clutch tonight (in 30+ degress in the garage....) Got it all off only to find that the clutch springs arent held in by bolts like all the you tube videos i have seen of clutch replacements but rather some sort of 'clip system' for lack of a better explanation. In short, I have no idea how to get the bloody springs and subsequenttly clutch plates in and out.

I still havent been able to track down a work shop manual for these bikes - can anyone tell me where might be the best place to try find one so i get this bike going again??

Thanks in advance for any further advice

[FJRider]

I bought and received a clutch fibre kit this week and have just drained the oil and taken the transmission cover off to get at the clutch tonight (in 30+ degress in the garage....) Got it all off only to find that the clutch springs arent held in by bolts like all the you tube videos i have seen of clutch replacements but rather some sort of 'clip system' for lack of a better explanation. In short, I have no idea how to get the bloody springs and subsequenttly clutch plates in and out.

I still havent been able to track down a work shop manual for these bikes - can anyone tell me where might be the best place to try find one so i get this bike going again??

Thanks in advance for any further advice

Just guessing here ... but you will probably need to compress the springs to release the clips. No doubt the manufacturer intended for a specialist tool to achieve this.

Kiwi cunning may prevail.

[Katman]

Hook something into the eye of the spring that's holding the retaining pin, pull outwards and remove the retaining pin.

Simple.

[awa355]

A TF mudbug should be one of the easiest bikes in NZ to get info on. I have often thought of getting one with wof/rego and using it to explore the back country roads around the Waipa / King country. Currently one on tme with rego and wof. Should be a fairly basic machine to maintain.

[F5 Dave]

Spring hook puller. Easiest made with an old spoke & a 3" bit sawn (if that's a word) from the end of a broom handle. (drill a hole in the wood & thread the spoke through retained by a nipple.

Sharpen the spoke eye so its just a hook & it will pull the spring easy. Use pliers to grab the pins so they don't PING off to some dark area.

[DeadeyeDent]

got it all fixed - needle nose pliers and some decent size split pins and I managed to get the springs and clips out. Rest was a breeze and its now changing smoothly.

Now to replace the chain and sprockets and by the looks of it the front forks are leaking too. Possibly should have saved up for something in slightly better nick aye:facepalm:

[FJRider]

got it all fixed - needle nose pliers and some decent size split pins and I managed to get the springs and clips out. Rest was a breeze and its now changing smoothly.

Now to replace the chain and sprockets and by the looks of it the front forks are leaking too. Possibly should have saved up for something in slightly better nick aye:facepalm:

Well done ... I think you're getting the hang of it ... :yes:

And NAH .... think of all the fun you would have missed. Time to start looking for the "Project Road Bike" ... :laugh: