Possible Clutch Issue

Hey All,

I did a quick search, but I wasn't able to find anything. I'm having issues getting my XJ550 into neutral after the motor is hot (30 minutes to 1 hour of run time). I've noticed that if I press the clutch lever on top of the cover forward, I am able to get it into neutral fairly easy. The issue is, if I adjust the clutch anymore, I'm afraid that it won't hold. Right now, it doesn't take a whole lot of effort to disengage the clutch (1/2" of movement on the lever). I haven't noticed it slipping at all, but the engagements aren't as crisp and sudden as they used to be.

Is it time for a new clutch, or is there something else at play here? Not being able to get the bike into neutral sounds like clutch drag. I'm going to mess around with the adjustment a little after I get off of work tonight to see if I can remedy it before picking up a clutch kit. Also, should I be okay in just getting friction disks, or is it absolutely necessary to replace the entire pack?

Thanks!

 

How many miles? How much free play in the lever? Sounds like you might just need an adjustment.

 

Around 24k. I have a small amount of play in the lever, but I've always read that you want a small amount of play. I'd be ecstatic if I can just get away with doing a adjustment. I will mention that I do need to do an oil change as well. Would that have any effect on the clutch?

 

from Factory Service Manual cable will show slack at ends

sounds like you are adjusted properly
you can use the adjuster at the clutch housing to reduce how far out the adjuster is at clutch lever
is.



Check your inbox sent you something

 

Yeah, that's about how mine is adjusted. It looks like it's time for a new clutch.

 

yup the closer to full out of the lever you get the closer your are to needing a new clutch 1/2 inch is not much

 

Well, I got Friction plates, Springs, and a Gasket ordered. I'm hoping that my steel plates are still in good shape. This is the first clutch job that I've ever attempted to do on a motorcycle (and I've never assisted with one either). I saw a couple posts with a little information, but I was wondering if anyone has put together a Write up on how it is supposed to be done. I watched a Youtube Video on a XJ600 Seca II, and it looks straight forward enough, but I don't want to be flying into this blind. Is there anything else that I'm going to need, aside from fluids/filter?

 

Fitz did a nice writeup:

http://www.xjbikes.com/forums/threads/clutches-101-part-1-the-400-550-600s-with-pics.29541/

 

It's pretty straightforward. Just be neat and meticulous about paying attention to how things come apart. Take pictures if you don't trust your memory, or if you think there is any chance it will not be going right back together. If you lay the bike on it's side, sometimes you can get away without draining the oil too. Use a set of calipers to measure the steel plates, there will be an acceptable wear limit on their thickness.

 

Quick question. It looks like the spring that sits on my clutch lever is broken. Is this a big issue or is it fine? I can't seem to find one for sale.

 

Yes that is an issue. Without it, your cable will never be adjusted properly. The spring is needed to keep tension on the cable when releasing the clutch and to endure the arm returns to the proper position. I would replace that before you take that clutch apart.

Post up in the wanted section or look in XJ4Ever's catalog/PM Chacal. I'm sure you can get one.

 

Any idea on what it's called?

 

removed info spring is its own part number item 28

Spring, Torsion
90508-16459-00

• 1981 XJ550H - Clutch Xj550h J K

 

Thanks!

I'm sending him a PM now to make sure that I get the right part.

 

Should be this guy.

HCP3208 OEM clutch pressure plate pivot axle shaft RETURN SPRING. Fits all XJ550, 1984-85 FJ600, XJ650, XJ700, XJ750, and XJ900 models. Each:

 

Thanks for the info guys. It turns out that my local dealer had one in their back room. I have no idea why they had one, but at this point I'm going to go buy lotto tickets, because winning was more likely than that happening.

 

was it just the spring or full arm assembly would you post the mfg part number

 

That diagram you linked is wrong, shows the parts in the wrong place. I think Fitz pointed that out too. Looks like it should be 90508-16459-00.

 

It was just the spring arm. I don't remember what the part number was, but they just called it a torsion spring. It's apparently pretty common and used across a lot of models. I think the arm itself doesn't need to be replaced at all. Just the spring.

 

I think what 550 was getting at was that the diagram made it look like only the whole arm was available, which is why I think he wanted the part number. That diagram and also the service manual is wrong if not just misleading.

How's the clutch now that you replaced the spring?

 

I haven't replaced it yet. It's been sprinkling on and off so I haven't had the desire to do anything lol. Tonight should be clear though, so I'll attempt it when I get off work. I still have Friction Plates, Springs, and a gasket on the way, so it'll get replaced on Saturday regardless. It is in need of an oil change too, so it'll pretty much be fresh after this weekend.

EDIT:
Part Number. I found my invoice in the car:
90508-16459

 

Thats a strange Yamaha part number...doesn't follow their usual format. Kinda looks like a Suzuki number to me.

 

The full number is 90508-16459-00, I think they dropped the last two digits for the invoice.

 

Ahhh that looks better haha.

 

I have noticed that on the online sites that the numbers have been changing formats


Push Lever Assembly first is obsolete 2 ed current

4G0-16340-01-00 3YR-16340-00-00

 

Well, I threw it on tonight and it didn't make any difference. I was able to adjust a little bit and am able to make it bearable, but it looks like the clutch was needed. This ought to be fun lol.

 

Right- Yamaha #s have always traditionally included a 3 digit prefix with at least one letter, and finished with a ...00-00/...01-00, etc. I guess it's conceivable that they would run out of combinations, but you'd think that they'd just start changing the suffixs'- like ...03-00, or ...11-00, etc.

 

same parts on newer bikes so the go with the newest modle as the xj fades from the customer base latest model

• 1990 RADIAN (YX600AC) - Clutch