Sticky Clutch

81 XJ550 and the clutch seems to stick when returning. When letting the clutch lever out it stops at a point when the lever isn't fully out, then I have to push it out to help it to go the rest of the way. This is a brand new clutch cable. Any clue on what is causing this? There are no kinks in the cable and service manual wasn't much help. It is missing the clip that goes on top of this linkage arm. Thanks!

 

Was it doing that before new cable?
Or is it hanging at lever?
Missing clip may be causing shaft to bind on spring at housing as seen in small picture that is not located in pocket on case. Use a piece of mechanics wire to hold the arm down in place of clip. Almost looks like spring is upside down.
Next step disconnect cable at bottom and using large pliers move the lever on the engine to see if it is internal problem.
And is it a genuine Yamaha cable, have you routed it correctly , low handlebars etc?

 

the clutch basket can get notches worn in it that can do that

 

I never checked the old cable. It's a barn find to learn maintenance on. Previous owner said when he parked it a year ago the cable had stretched past adjustment. I did move the lever by hand and it seems smooth and does not hang up which led me to believe its somewhere between the spring and clutch lever. It is routed properly. I did just find Bigfitz52 posted some up close photos of his (different problem but same source) and its clear the spring loops over the top of the lever. It looks as if the spring on mine has broken off where it goes on top of the lever so my thought is the spring is A: not seated correctly due to circlip not pushing it down and B: does not have proper tension due to missing the piece of spring that goes on top of the lever. This is however my first time DIY'ing a bike so I could be completely wrong.

 

do this

 

Polock, it moves fine then. Should I still pull the cover to check for a notches worn in the basket? If so when putting it back on should I put a dab of anti-seize on the allens? I appreciate the advice!

 

Did you properly set the arm and adjust the cable? Sound like there isnt enought tension

 

i would think the internal clutch springs are way stronger than any other spring in the system and wouldn't need any help returning the arm.
maybe loosen the whole switch/clutch housing, rotate it up so you can see the barrel/cable operate.
the basket notches would hang up with whatever operated the lever

 

If that spring is broken it's still available from Yamaha. Get that before you tear everything apart. Torsion spring #28 in the pic. Post a pick of spring it does look like it's upside down

 

replace that spring . also did you lube the new cable when you installed it?

 

I too was going to say lube new cable.

 

Will be re-lubing the new cable. Thanks for helping me identify the spring Toomanybikes! I have sent an email to Len to see if he has one, Len has really helped me out a ton and gotten me parts super fast so I'd love to give him more business. I'll grab a pic of the spring currently when I head out to the garage.

 

Here is the current spring Toomanybikes.

 

Yup broken

 

After I finished putting the cleaned carbs back in tonight I thought I'd stare at this for another 20 minutes and heres my next newb question. Is this shaft suppose to be free like it is or is there an internal spring that should return it as well? Really appreciate all the help!

 

it is free the throwout shaft has a spline on the end that connects to the "pull"rod" that when the throwout shaft isrotated pulls the clutch.
theres a thread about it

CLUTCHES 101-Part 1: the 400/550/600s with pics

 

That external return spring has to be in place. Without it you will have slop in the linkage that you will not be able to adjust.