81 xj550 with a tight clutch

I have a 81 xj550 with a tight clutch. I have been riding it now for 2+ years. It sat for 3+ years before I bought it. The clutch has always been tight and hard to pull in. Not like a newer bike were my 6 yr old can squeeze the clutch in. It takes a firm grip to pull it in. I have never thought much of it because it has always worked. Last night however I was doing some preventative maintenance and found that my clutch cable was splintering, about an 1.5 - 2 inch from the handle. I have about half of it left. It looks like I should have done my preventative maintenance earlier.

I am thinking that the tight clutch has something to do with this but not sure. I might not have done a good enough job of lubing my cables. Does anyone think that the tight clutch could be the problem and if so where do I start. Like I said earlier. The clutch has always worked I have no problem going through the gears. Only the occasional "klunk" into 1st gear or into second, but only when I am trying to get into neutral. Any help would be great.

Thanks and good ridin'

 

Oh ya one more bit of info. I replaced the clutch cable when I first bought it in 2008 and last December when I put my new handle bars on. The cable wasn't routed to tight and not to close to the pipes. It has just always been tight to pull.

Keep em turnin' and burnin'

 

BEFORE ANYTHING ABOUT THE CLUTCH: You said you've been riding it for a couple years, and it sat for 3+ before that. Have you checked the rear brake for delamination? http://xjbikes.com/Forums/viewtopic/t=15874.html You CANNOT go by feel, you need to pull it apart and look.

Now about the clutch. First off, a cable that was fraying or hasn't been properly lubed can indeed make the clutch tight to pull in.

Your problem may not be the clutch itself, it could be/have been the cable all along. They do need to be lubed when brand new and then every couple of years thereafter.

Another thing to keep in mind: If you're trying to "activate" the clutch manually at the lever on the case, it will be almost impossible to move by hand. This is normal, it needs the mechanical advantage of the lever to work.

That being said, with a bike that has sat for a while, anything is possible.

I have a question, then some basic info and advice:

How many miles on this puppy, and how many of them are yours?

WFWD: (What Fitz would do)

Step one: Replace clutch cable, but be sure to properly LUBE this one before or immediately after installing. DO NOT USE WD40; use a high-quality automotive/industrial lube or light motor oil. I use a cable-luber tool and aerosol Tri-Flow lube.

Step one and a half: While replacing cable, disassemble lever from perch; clean perch and lever pivot/sliding surfaces thoroughly, and relube with a light, waterproof grease. This is a perfect use for that sticky white lithium grease that's sold for automotive body hinges, etc.

Step two: Properly adjust cable-- run the adjuster at the perch in about halfway, and then get things adjusted down below so that you're close; then do your fine tuning at the lever. You want 1mm-3mm MAX free play at the lever end.

On the 550, the clutch activating lever should "stop" when pushed by hand, at the position indicated below: (Note alignment with "pip" on case.)




That should take care of any cable issues; if the clutch continues to be difficult to pull in, or misbehaves (the "clunking" you've described is due to clutch drag, some is normal at times) you may need to pop it apart and have a look at what's going on.

If a PO's been in there and mis-assembled it, or if the hub nut has come loose, or something's excessively worn, it could be causing it to be overly stiff as well.

The 550's clutch has some interesting "oddities" to its design; this should be everything you need to know if surgery becomes necessary: http://xjbikes.com/Forums/viewtopic/t=29541.html

One last question: Your 550-- since you're in the UK, is it a Maxim or does it look like our Secas?

 

bigfitz52,
Thanks for the reply on my post. Let me aswer your questions.
1. 21,993 and a little over 4,000 are mine.
2. I am only stationed in the UK, I bought the bike in Utah before being stationed in the UK. So it is a Maxim from the states.

When I got it in June, 2008, I replace the clutch cable first thing. I did lube it with proper cable lube. Last December I made some changes to the bike and put new handle bars on it. With that came another new clutch cable. I lubed that one as well with cable lube. The clutch has always been tight to pull in. I will admit that since plutting the new cable on last December I have not lubed it since. Being here in the UK with all the rain I should have lubed it a while ago. There is realy only 1-2 months out of the year that I don't ride to work every day and at work the bike is parked out in the elements.

Thanks again for the help and the reply. Since I have some down time waiting for a new cable I will be checking out the rear brake for delamination. Thanks again.

 

Excellent; thank you. At that mileage, the clutch will need attention soon anyway; so if the new cable doesn't completely cure the issue, pop it apart to have a look. It's all covered in my article.

 

bigfitz52, Thanks again for the help. I got the new cable on order and it will be about 3 weeks before I get it. That will give me some time to looking around on the bike. Do you know where I can get a gasket for the clutch cover at? Thanks again

 

The best source for parts is our resident parts guru; PM member chacal, send an email to info @ XJ4Ever.com, or click on the logo/link in the banner at the top of the site.

 

I would make you right, there, Fitz, if it wasn't for the shipping to the UK.

This will be your best bet

 

He's in the US Military. Postage to APO's is different, by exactly how much, I don't know. But not the same as shipping to a "civvie" in the UK. It's worth an ask.

 

Fitz, the part costs 4 UK pounds, if it was a set of rings I'd say do the exercise.