Clutch Disassembly/Reassembly

I noticed that the clutch on my bike ('81 Maxim 550) wasn't working like it should. Harder than usual to roll in first gear with the bike off and clutch in, too much "creep" when stopped in first gear, etc. Adjusted the cable (it had absolutely no play in it) but the problem was still there. So I drained the oil and took off the clutch cover. I found this diagram:

http://www.ioffer.com/i/Yamaha-Maxim-XJ ... -139793555

and made sure that I wasn't missing any parts or anything; everything seems to be there. I reassembled the clutch exactly like the diagram showed, but now I can't even get it to disengage. I thought that I may have tightened the springs a bit too much, but I loosened them to the point where I couldn't get the cover back on and the problem persists. I'm really at a loss here; any idea where to go next?

 

First off, for your bike, that diagram is wrong.

corrected:




Next, did you "stagger" the tabs on the plain plates, as indicated here:



(This diagram also indicates the correct placement of the single clutch boss spring.)


Were you careful to line up the "dot" on the pressure plate with the dot cast into the basket?




Once the cover is back on, REMOVE the lever, turn the throwout shaft CLOCKWISE until it stops, and reattach the lever so that you are positioned here when you press the lever against where it stops: (note position of lever relative to little "box" cast onto cover)




The springs' bolts get torqued to 5.8 ft/lbs; and should be tight.

You WILL NOT be able to operate the throwout lever by hand, even with a pair of monster pliers it's difficult. You need the mechanical advantage of the clutch lever and cable.

 

Thanks for the help! I got it all put back together according to your pictures and it works wonderfully. The only difference is that my clutch has 8 friction pads and 7 metal plates, whereas your picture has only 7 pads and 6 plates. I don't see this as a big problem since it works now, but it is a curious discrepancy. Also, the diagram shows a "special friction plate for the clutch boss spring". I had one plate that was wasn't as wide as the others; I assume this is the one you're referring to?

 

Yes, the one friction plate with the larger ID is for the clutch boss spring, it belongs in the third position in from the outside.

Yep, the plate count IS short one in the F*ed up diagram, too. Curiously, we heard from one of our UK members whose clutch matched the uncorrected diagram.

I'm glad it worked.