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85 XJ700 Clutch Conundrum

Discussion in 'XJ Technical Chat' started by elliott, Apr 23, 2016.

  1. elliott

    elliott Member

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    Hey guys, I'm in the middle of replacing this clutch with brand new friction plates, driver plates, springs, bolts, and crankcase cover gasket from chacal. I followed fitz's guide, but I have run into some loving obstacles.

    So I've got all the new parts in, and the crankcase cover on. The throw out shaft is rotated fully clockwise so the pull rod is flush to the pressure plate. Here's my problem though, the throw out shaft won't physically go any farther clockwise - it's like the clutch is frozen shut or something. Are the 6 spring bolts over tightened or something? What have I do wrong?

    Also, man the service manual is really vague. The exploded diagram alludes to all sorts of things i didn't pull out of the original clutch (and I've ridden like 8000 miles on that one). Like i never saw a "clutch boss spring" in there. All I pulled out were 8 friction plates, 7 driver plates, and the original springs and bolts.
     
    elliott, Apr 23, 2016
    #1
  2. a100man

    a100man Well-Known Member

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    On the 550 the clutch spring bolts are real low torque like about 7 ft/lbs. Get a torque wrench and check your settings..
     
    a100man, Apr 23, 2016
    #2
  3. XJ550H

    XJ550H Well-Known Member Premium Member

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    XJ550H, Apr 23, 2016
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  4. XJ550H

    XJ550H Well-Known Member Premium Member

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    are you trying to move it by hand or with the clutch lever?
     
    XJ550H, Apr 23, 2016
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  5. elliott

    elliott Member

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    I was just trying to move it by hand. Also, I didn't disassemble anything past the last friction plate - so right before the driver plate [10] captured by the wire clip [9]. So that must be why I didn't run into it.

    The bike's been sitting since last night with no oil in it, so I'm assuming I should start over and re-dredge the plates in oil?
     
    elliott, Apr 23, 2016
    #5
  6. PilotSmack

    PilotSmack Active Member

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    It's a real PITA to move by hand. Give it a whirl with the cable connected.
     
    PilotSmack, Apr 23, 2016
    #6
  7. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    ^^ what he said. You need the mechanical advantage of the clutch lever.
     
    k-moe, Apr 23, 2016
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  8. elliott

    elliott Member

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    You guys were totally right. Even so, I took the whole thing apart again, re-dredged everything in oil, put it back together, filled it up with oil and took it out. Unbelievable difference. The old clutch was so "casual" feeling. The new one is far more assertive. Love it.
     
    elliott, Apr 24, 2016
    #8

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