Clutch Knock When Pulling In Lever - XJ900

So I've been furiously piecing this beast together and every time I touch it I find something else... Damn useless PO...

Anyway I thought I was ready to go for a ride after putting a new Motobat in it today... Fires up first time and runs sweet

Go to put it in to gear and clunk, bike stops so I adjust the clutch up and after a couple more stalls and adjusts I start the engine and when I pull in the lever I get a loud knocking sound from the clutch side cover (Feels like basket is hitting cover). Note the sound only happens when the clutch is disengaged.

This engine has sat with fairly new oil in it for about a year... I only heard it running before then and have no idea how long it's been since it's last ride or when it last worked properly

I've read Ricks Adjustment thread and I don't think it's in the adjustment...

Time for a replacement? Any other suggestions before I pull it down for a closer look?

 

It sounds to me like you might have a dry plate issue going on insde. Only the bottom of the plates had oil on them while the motor was sitting. For the price of a paper gasket it is worth the trouble to open it up. Just to take a look to make sure everything is in good shape.

Ghost

 

I agree, gasket is only about $10 AUS.

Definitely worth it just to check the plates and springs out.

 

or the basket is loose. you are gonna have to go in and look. sorry.

dave

 

Something's not right. (Obviously.)

Gonna have to pull it apart and look.

Be aware of something: It's not unusual in a right-side tipover/crash for the brake lever to punch through the case. If it punches through with enough force, it can actually BEND the clutch basket. One of my bikes had this problem when I got it. (I'm assuming your brake lever lines up with the case like a lot of the XJs do.)

It's also possible that the hub is loose (my other bike had THAT problem when I got it.)

You could also have a damaged or worn out "wafer bearing" on the throwout shaft, or a cracked pressure plate. Best to have a look.

 

Well i found it... Pretty much straight away

Classic case of being left for too long... All the plates were stuck together

I'll give it a clean up, re-assemble and see how it is after that.

Thanks for the suggestions

 

Fitz... Your Clutch 101 thread is a god send & it doesn't even cover the 900

Thanks

 

Sure it does; the principles behind it anyway. If anything, the 900 is simpler.

I would still make sure the clutch basket spins "true." Spin the motor over with the cover off (and TCI disconnected so it won't start.) However, be sure to strategically place some shop rags to catch oil drop fling.

 

sounds kinda like a weird issue i have - if i put my maxim intro 1st slowly, with the clutch lever all the way in, it snufs out/kills the engine.


if i put it into gear kinda quick, it makes a "clunk" and then is in gear, and doesn't kill the engine.

any ideas? i can make another thread, but i figured it was similar, and the op has already found the solution to the problem.

fitz, where may i find this clutch write-up that people speak of?

Thanks
1

 

It's in "XJ FAQ Suggestions" here: http://xjbikes.com/Forums/viewtopic/t=29541.html

While it's stated as being for the 400/550/600s, the basic layout and parts breakdown are common to most of the "airhead" bikes except the 1100. Most of the other bikes clutches are actually a bit simpler, with no tabbed plates or clutch boss spring to worry about.

It sounds like your issue could be as simple as just needing adjustment; or you might also benefit from a pull apart/clean and inspection.

 

Awesome! Thanks Fitz!

 

hmmm so I got it back together and working... But it's still not right... Worked ok for long enough to get around the block, then it started making the knocking sound again... I wonder if the plates are still sticky from sitting for too long... It stalled the motor and now it won't run

I had some other really noisy chain noise from this motor too... I suspect it may be fubar... dang

 

There was a forum post a few days ago that had a clatter noise from the case. It turned out to be a chain guide of follower, but I can't remember which. Gimme a few minutes, I'll do some digging...

 

I gave up and put it up for sale

http://www.trademe.co.nz/Browse/Listing ... =437280723

 

Somebody down under is going to get a hell of a deal

 

Awe man, and that is such a SUPER SHARP looking bike. I know that I don't know the whole story but it's a darned shame to see you selling that bike.

Honestly, I hope that you have second thoughts and decide to take it apart again...unless there's a part of the story we don't know that makes it justified to sell. You just know in your heart that it's not a really big deal to fix unless again, there's another part to this story.

Good luck

jeff

 

Yeah, I was gonna say it does seem a bit premature to me as well.

There's another chain or two in there (I'm assuming you've decided it's a primary chain issue; I don't think it is) remember not only do you have the camchain but if the 900 is like the 650 and 750, the OIL PUMP is driven by a small chain behind the clutch somewhere. Somewhere easily accessible.

It's your decision but it seems a might hasty.

 

I was prepping it to sell anyway... Has to go before the 6th of Feb when we move countries...

So went in to the garage this morning, put fresh gas in the tank, sprayed some ether at the air intake and what do you know? It fired and ran like a dream...

Took it down to the gas station and filled the tank and now it starts first pop and runs sweet.... there's a lot to be said for fresh gas

 

well hot dang, change that ad!

 

Several times, ... I have has to pull the Clutch Cover to "Re-seat" Yamaha Part 4H7-15412-01-00 COVER, OIL PUMP

(31) 0n this Schematic

http://www.yamaha-motor.com/partviewer/ ... _-_1983%29