83 550 Maxim clutch adjustment

I removed the clutch of my 83 Maxim to replace the spring that centers the shift lever and now the clutch won't release. I've replace the cover every way I can and when I adjust the hand lever where it pulls the clutch lever all the way, as far as it goes, because it's up against a stop inside, the clutch still won't release.

The only thing I can think is that I need to put some sort of spacer (washer) between the inside of the pressure plate and the throwout bearing. There seems to be a lot of free play before the puller starts acting on the plate.

Any ideas?

Art

 

Adjust it correctly.

TAKE THE LITTLE LEVER COMPLETELY OFF. Trying to get it positioned correctly with it on as you install the cover is an exercise in futility. Yes, I know that's what the book says but it's goofy at best.

Rotate the throwout shaft clockwise, when viewed from above, until it stops. The "pull" rod is now up against the back of the pressure plate.

Re-attach the little lever so that when you push it forward, it stops as shown in the pic below. Note position of the end of the little lever in relation to the rectangular "pip" cast on the case. THIS is the correct "starting point" for the throwout lever.

Set handlebar adjuster halfway in/out. Adjust at the bottom set of nuts (on the cable) to eliminate slack. Fine-tune at the handlebar lever.





This picture is from the 550 clutch "how-to," I hope you got the plates back in the correct orientation: http://xjbikes.com/Forums/viewtopic/t=29541.html

 

Thanks for the quick reply. I thought about doing that but haven't tried that yet. However, here's the problem. No matter where I put the lever, when I turn it until it hits at stop, which is, I think, when the pull rod gets to the limit of it's travel inside the clutch cover, the clutch still won't release.

I believe I got the plates in the right position. I took the pressure plate off, then pulled the whole thing, steel plates and fiber plates, out together and didn't separate them until I started to put them back in. I guess I need to look at the parts breakdown and make sure I didn't leave anything out. I think that the only things on the clutch puller are the throwout bearing and a steel washer. Isn't that correct?

It feels like the puller is using up too much of it's travel in free play then, when it makes contact with the pressure plate, it can only travel a short distance before it hits the stop on hte inside of the cover.

Thanks

 

You're absolutely correct.

The method I describe above sets up the lever so it is starting its pull with the pull-rod against the back of the pressure plate. From the sound of things, your "starting point" is too far back, so you're using up lever travel just getting the pull-rod up against the pressure plate. It needs to START there. Setting it the way I descibe will accomplish this.