clutch return

hello everyone, i recently started working on my first bike. i attempted to change the clutch, sprockets and drive chain, but ran into a couple of problems. hoping to learn a few things.

with the exception of a shotty chain breaker (NO THANKS HARBOR FREIGHT), i was think i successfully changed the sprockets and drive chain. haven't had the chance to test it, so i can't be sure.

i ran into a problem with the clutch, after i got everything back together the lever wouldn't return. the cable seems to be in good condition and i lubed it just to be safe, but even when the cable/lever isn't connected the clutch will not return. what makes it return besides the spring located on the clutch case?

any insight or advice is greatly appreciated!

 

Bben, welcome to the forum.

You are on the right place to ask questions about your XJ bike. You may want to add the bike model you have on you signature settings so people know what you are talking about.

I am sure somebody will respond as soon as you give a bit more details on what bike model you are working on. I can't help you with your bike since I don't do bling (don't like chains my bikes are shaft driven).

Good luck.

 

Thanks a lot!*

 

Hey bben,

Not sure if I can be much help but I'll try. I recently rebuilt my clutch and it seems to be working fine so I guess I did it right.

First thing to ask, Do you have a manual to refer to? If not, go to ebay and get one for $10-30. Best money you will spend. Between that and the help you can get here, you will be in good hands.

Questions about work you did.
Did you adjust the free play for the handle?
Did you get the spring on the outside installed properly?
Can you push the lever that the cable connects to very easily? It should be really hard to push. You should NOT be able to push/engage the clutch my just pushing on the lever by hand.
If you CAN push the lever, then my guess is that you didn't get the PUSH ROD set properly. It is the rod that has grooves on one side. The lever assembly has a threaded section on the bottom that connects into these grooves and pushes/engages the clutch. When the clutch is released, the 5 springs on the clutch plate should push this rod out and RETURN the clutch handle to the resting position.

I am not much of a mechanic and not sure if what I'm saying is the way it actually works, or if it makes sense. I'm just trying to work it out through my own misguided logic.

SO, if anyone can chime in with corrections or better advice, PLEASE feel free to help me out.

 

It sounds to me like you've hit on the solution, it just needs to be explained more thoroughly.

The throwout lever needs to be repositioned on the shaft for a correct "starting" point so that it has the proper amount of "throw."

This is covered in my clutch article: http://xjbikes.com/Forums/viewtopic/t=29541.html See the last pic in the article.

 

many thanks for your help guys! unfortunately i logged on a bit too late, i went to work on the bike straight out of work and ended up breaking off one of the inner clutch basket posts (what the pressure plate bolts thread into). i'm now in search of this part so that i can try and get the bike back to working condition.
i've been attempting to follow my cylmer manual, but have obviously missed something. any idea what could have happened? to test the clutch, i slowly coasted the bike in neutral and shifted into second (similar to a bump start but not as fast), but before i had even released the clutch lever the bike stopped coasting (upon entry into second gear) as if the clutch was too tight or had never loosened up when i pulled the clutch lever.
hoping this is just a new-bie mistake. i was comparing my clutch to my friends and it didn't seem to add up. when he pulled on his clutch lever, the friction plates loosened up to the point where they could be moved slightly. since installing the new parts, mine have never done this.
i know it's something i screwed up because it was functional (with slippage) before i started working on it.
any input, knowledge or help is greatly appreciated!

 

hey windlover, thanks for the help! i do have a clymer manual. i did mess with the lever free play and it seemed to be ok compared to what the manual suggested.

i just bought a new spring for the outside of the clutch case (under the clutch arm). was pretty excited that it was only $4. lol

i could push the lever by hand, but it was not easy by any means. i adjusted the torque of the pressure plate bolts until i could not move it by hand, but had no problems when it was hooked up to the lever.

your "misguided logic" is a definite help in my troubleshooting process!

 

ps.

THANKS bigfitz! your clutch article is great! there were a few things that the clymer manual had left out. will definitely be utilizing your article once i get the new part in.

 

EBC is currently running a Sale on Carbon Fiber Kits for Yamaha Bikes.

Although "XJ" does not appear in the Pull-down Model List, there are a few that might share the same Parts as ours.

Don't let your enthusiasm to go gunning-around with a brand new clutch be dampened by not being careful torquing Pressure Plate Bolts.
I use LockTite.
What the heck.

Typical EBC Offer:
http://www.btosports.com/p/ebc-yamaha-c ... 4AodHxcA7Q