whats with this clutch?

I replaced my clutch plates and reassembled, but something is off. I put the clutch cover back on and try to pull the clutch, but nothing pulls. I have about an inch of play in the bolt that connects to the clutch lever. I believe the clutch is stuck in the open possition. My terminology sucks so heres some pics.

 

hint: that mark at 8:00 position don't go there

 

Im pretty sure it does, I had to line it up with the mark behind it, which varies with whatever position it turned to. Took it apart and put it back together, and used a screwdriver as a lever to open the clutch instead of the clutch cable. My half assed assembly of the clutch handle and cable routing wasnt letting me get enough force on the clutch lever. But why am I still only able to shift to second... see you all tomorrow I guess.

 

Hey, Lou:

When you put the Clutch Cover back on the Engine ... you have to rotate the Throw-out Rod and take-up all the Free Play before you attach the Throw-out Arm back onto the Splines at the end of the Rod.

It's a job that makes you wish you had three hands.

I wrap a shoelace around the Rod a few times and pull on the shoe lace to get the Rod rotated all the way clockwise and then tape the shoe lace to the Cover to hold the Rod while I fit the Arm back on to have as much Throw as the Cable will provide.

 

Hope you figure the problem out. I'll be watching this space very close. I'll be doing this Sat. I assume this is the first time you've done this. How long did it take you?

 

The bit you're pulling on in pics 2 and 3 is the throwout "rod" and its gear teeth need to be positioned toward the rear when the cover goes on. Then as Rick says, you rotate the throwout shaft clockwise (which pulls that piece out against the inside of the pressure plate.) THEN refit the lever in the correct position. I use a rubber band rather than a shoelace to keep the rod from trying to turn back the wrong way while you put the lever on, and just snip the rubber band once it's in place. Your problem is that the throwout rod was not pulled up tight against the inside of the pressure plate when you refitted the release arm, so it's pulling "air." I couldn't for the life of me figure out the mechanism (the book keeps calling it a PUSHrod) until I took mine apart. Neither the Clymer nor the factory manual are super clear on what you're trying to accomplish upon reassembly.

 

I figured it out last night, and had good luck getting the gears aligned, and then turning the throwout rod to kind of pull the clutch cover back on. Everything turned out fine. My clutch handle tightener is striped, and the clutch cable wasnt secured, and was leading me to believe the clutch was stuck, but levering the release arm proved this wasnt the case. thanks for the tips.

 

An hour and a half to take apart, load up plates, and put together

 

Ill throw this in here so I dont need a new thread... I cant shift past second, even with clutch fully pulled. Could this just be from not having any oil in there yet?

 

Is it not shifting as you move the rear tire? If not, turn the rear tire and you should be able to shift again. Lack of oil will not keep you from shifting.

 

On the 550 if you move the shift lever with out the clutch cover the drum detent roller will fall off the drum cam and get jammed. I don't know if the 650 is the same but it's worth looking if you still have it apart.

 

Just giving this a bump cause I may be having the same problem.(82 XJ650) When my bike is off i can up shift and downshift without pulling in the clutch Lever. I totaly removed the clutch cable and had the same results. I've own other XJ's and Don't think this is normal. I haven't tried shifting gears without the lever for fear of busting my @$$. I will try shifting it when on the center stand.(when the weather gets warmer). Meanwhile I'm open to suggestions.

 

Tito, with the bike off you should be able to shift up and down (possibly having to rotate the back wheel to get to the next gear) without using the clutch. You can even do it with the bike running if your good at it

Anyway it's nothing to worry about

 

Ace, thanks for the reply. Just wanted to clarify that I am Not pulling on the clutch lever while the bike is off. Should it still shift? I often ride clutchless to get me going a lot faster and i feel like I'm putting less stress on the plates.

 

I just noticed my wording on my first post.

"I haven't tried shifting gears without the lever for fear of busting my @$$. I will try shifting it when on the center stand.(when the weather gets warmer)."

What I ment to say is I haven't tried shifting gears sitting still while the bike is running without using the clutch for fear of busting my @$$. I have an xs650 that when i took out the clutch rod there was a little ball bearing that fell out and i didn't notice, and when i put it together and went to go for a ride i pulled in the clutch popped it into first and WAMMO, It lurched forward violently and then died. I knew it had to be something with the clutch. I found the little ball and put it back in and then all was well.

 

Yeah Tito you should be able to do it without the clutch with the bike not running. Like I said though you might only get one or two gears then you will have to move the back tire to get up to the next gear

 

OK guys, i jacked the bike up so the rear wheel was off the ground. Started the bike and now with no clutch cable attached the bike still goes into all gears while idleing, no clutch cable attached. I deffinitly know this should not happen. Any ideas?

 

When it "goes into all gears" with the engine idling, is the back wheel spinning (progressively faster) with each gear change?

If so, then everything is FINE. You can shift up and down, clutchlessly, with the engine idling and no load on the rear wheel, but it will spin the wheel.

Is there an actual PROBLEM or are you just trying to figure out all the idiosyncracies of a wet clutch?

 

The tire spun faster in each gear and a noticable strain was put on the motor.( clutch cable disconnected)
This is the first time putting this bike on the road, I had an xs650 that shifted into first without a clutch while on the ground and it leeped forward and stalled while i was on it and my balls rang the tank , so i don't want to do that agian. I haven't tried this bike for that fear. Knowing that with a load( my 180 pounds) the bike will not shift into gear while i am on it i'll give it a go. gonna stuff my pant though. Hehehe.

 

upon your expertise. i jumped on the bike and took it for a ride. ya hooo! there is nothing wrong with it.heheh. one thinig . i believe the starter relay is on it's way out. all it would do is click but no start. i took the starter wire off the relay and touched it to the positive of the bateryy and she starts. any thoughts?

 

Disassemble, check and CLEAN (religiously) all of the connections related to the starter relay, and the associated wiring. It COULD be the relay but is more likely a cruddy connector somewhere.