Draco what do you take from the list of parts to replace according to the dealer?
all steels and fibers
clutch cover gasket
oil pan gasket
clutch hub nut
outer clutch basket
oil pick up screen
Read most of this last night - Did anyone check for metal in the oil or oil filter from the "supposed stripped gears"? If all six gears are gone there should be some foreign matter in the oil.
The dealership obviously doesn't know what's wrong, so they are planning on replacing the entire clutch assembly and cleaning out the bottom of the pan. If I was Suzuki, I would reject the request as well. They are not replacing the transmission, so the statement they made that "all 6 gears were gone" is false. "If" the outer basket failed and needed replacing, there are big issues. Baskets don't fail, they shatter, and when they do, many many pieces of metal end up in the pan and will quickly cause rod bearing failure. If you can start the bike up and it doesn't make tons of noise from the clutch, I doubt very much that the basket shattered. The baskets are typically good for 260 HP, and you aren't making that much power. You can pop the cover off yourself and see if the outer basket is busted (very unlikely), but if it is, I would want a new motor; not a new clutch.
Again, I believe you have a problem with a clutch master cylinder, or you had a failure or backing out of the studs / springs in the clutch. Just my opinion.
They did see metal in the oil, but the pick up screen apparently kept it from getting in the the engine and causing damage.
The dealership obviously doesn't know what's wrong, so they are planning on replacing the entire clutch assembly and cleaning out the bottom of the pan. If I was Suzuki, I would reject the request as well. They are not replacing the transmission, so the statement they made that "all 6 gears were gone" is false. "If" the outer basket failed and needed replacing, there are big issues. Baskets don't fail, they shatter, and when they do, many many pieces of metal end up in the pan and will quickly cause rod bearing failure. If you can start the bike up and it doesn't make tons of noise from the clutch, I doubt very much that the basket shattered. The baskets are typically good for 260 HP, and you aren't making that much power. You can pop the cover off yourself and see if the outer basket is busted (very unlikely), but if it is, I would want a new motor; not a new clutch.
Again, I believe you have a problem with a clutch master cylinder, or you had a failure or backing out of the studs / springs in the clutch. Just my opinion.
Everyone is making this way to complicated. Others have had this problem too and I'm telling you, AGAIN!!! It,s the pin in the lever for the clutch master cylinder that has gotten cocked and keeping the clutch released.