Newbie question after rebuilding bike - bits left over.

Hi all,

As you can see i'm new to this forum, I'm from the UK, and last year i bought a 1990 XJ600 (dunno what you call it in america) and have a question about it.

Over the winter i mentioned to my dad that i was gonna strip her down, clean her, and build her back up again. BIG mistake. the next weekend i came home to find my bike in bits! my dad had decided he was going to help me strip it down for me. now this wouldn't normally be a problem, but my dad decided he couldn't be bothered organising the nuts and bolts he pulled off the bike, and decided to put everything into one big pot.

She's all back together after over a week of me struggling with the haynes manual and the little bit of common sense i have. However i have 2 springs left over that i can't work out where they go.

1 is a pivot spring, which i THINK is a rear brake return spring, however i cannot find a picture or anything in Haynes that shows me how it fits on.

The other is more difficult. it's a return spring about 4 inches long, with a long straight piece before the spring about halfway down. I already have a spring on my centre stand and side stand, so i don't think it's from there. Have any of you any idea where it could go?

Any suggestions welcome, and thanks for the help.

Insanity (james)

 

The long spring sounds like the rear brake pedal return spring.

No idea about the other one - your brake drum idea sounds okay.

Welcome to the forum.

 

Maybe if you take some pictures of the parts we may beable to help better.

 

Aye, i will do this weekend, and post them on monday.

Just want to say, it's taken me a while to find a decent XJ website, so thanks for any help.

 

Could the other spring be off the side stand? Just a wild guess.

 

How about the clutch return, Where the cable connects to the lever on the case. Spring goes under the arm. The other might be the brake switch spring. It connects the barke lever to the brake switch.

 

Here's the two springs that i have left over.

Side stand spring is on, brake switch spring is on, centre stand spring is on.

I really do think one of them is the rear brake lever return spring, as there is a hole at the top of the lever, but which spring it is i do not know.

 

Ok Here you go.

The top spring is the rear brake pedel spring it fits on the brake lever itself inside the foot pegs bracket.

The lower spring is the 2nd side stand spring that fits inside the larger spring you have allready fitted.

Cheers

Colin

 

Edit to above post.
On looking at it a second time I may be wrong about the top spring, it may go on the rear drum lever, rather than the peddle.

My wifes 550 Maxim's brake peddle spring looks a little heaver duty, and larger. I have also seen springs like that on other rear brake dum actuating arms.

C.

 

The top spring looks to me like it's the one that goes on the clutch arm where the shaft goes in to the engine housing.

 

I agree with Alive,

The top spring is the clutch arm return spring located on the top of the clutch cover.

The bottom spring is actually the inner spring for the sidestand.

There is an outer (larger) and an inner (smaller) spring. The smaller spring fits inside the larger spring.

Hope this helps.

 

Top spring is the clutch lever spring.

 

Hey guys,

Sorry for the late reply, i've been away with work.

Thanks for the replies, i will have a look at fitting them on the weekend.

 

If you worked along with some of the Jokers I've had to work with, in the past ... the Top Spring would be the Clutch Throw-Out Arm Return Spring ... and, there'd be several other springs, bolts and fasteners that practical jokers left on the bench ... just to liven-up the shop some.

The cruelest thing to do is save the plastic bag that a crankshaft thrust washer comes in ... clean-off and re-bag the old one ... and leave it face down under the Manual ... to be found during clean-up!!!

 

Thats funny, I am one that likes a good practical joke. And thats a good one. :lol: