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Clutch rattle fix (XJ550)

Discussion in 'XJ DIY How-To Instructions' started by LarryMc, Nov 21, 2017.

  1. LarryMc

    LarryMc Active Member

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    While I had my XJ550 apart installing my new clutch I decided to address a known problem with many bikes of the same era. It seems the oil pump gear on the back of the clutch basket has free play from the dowel pin that secures it from rotating. This small amount of play transfers into clutch rattle noise. On my CB750 this noise was especially loud and annoying as hell.
    Simply remove the gear and press part of a roll pin around the protruding section of the dowel, reassemble, done. You'll notice the chugging noise these bikes make at idle has greatly reduced, you'll still have some, IMG_3811.jpeg IMG_3814.jpeg it was the gear on the back of the clutch basket chugging back and forth.
     
    k-moe and chacal like this.
  2. Trvpstar

    Trvpstar Member

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    Apparently these dowel pins are hard to find, what did you use to replace them? Mine is rattling as well
     
  3. XJ550H

    XJ550H Well-Known Member Premium Member

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    order from dealership or our supporting vendor or any online parts house

    PIN, DOWEL
    93605-10108-00
    $3.55
    $2.39
     
  4. LarryMc

    LarryMc Active Member

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    I used a cut down roll pin it was a very tight fit.
     
  5. a100man

    a100man Well-Known Member

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    Changing the oil so I thought I'd have a look at this too. Got the clutch off and indeed the oil drive gear can move about 3 -4 degrees on the factory dowel. The dowel though measures 4.8mm on my verniers the hole in teh hub similar but it is not tight at all.
    meanwhile the slot in the gear measures abiout 5.2 mm so that's where most of the play is. To 'wrap a roll pin around the dowel' as suggested must have meant turning down the dowel first but there is no mention of that.
    I think fitting a roll pin only will eliminate the slop to some extent. Did anyone other than OP do this 'fix'?
     
  6. a100man

    a100man Well-Known Member

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    OK, another general 'Google' and I found this.. relating to Seca 2/ Diversion model..
    commenters refer to using a 5.5 mm drill bit as a replacement dowel, which seems large o_O
     

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