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83 XJ550 Unable to adjust clutch correctly after replacement

Discussion in 'XJ Technical Chat' started by RiotFawk, Feb 15, 2026 at 5:12 PM.

  1. RiotFawk

    RiotFawk New Member

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    I was able to get a new set of friction plates from Yamaha and aftermarket springs. I pulled everything out and only replaced the springs and friction plates, installing everything to my knowledge as it came out.

    After failing to cut out a new gasket a couple of times for the clutch cover I finally was able to get everything back together.

    Now, i can either adjust the clutch so that there is some free play in the handle as there is supposed to be, but even with the clutch pulled in all the way the bike still rolls forward in 1st. Or, I can adjust it so there is no free play but the clutch disengages (albeit with the engagement very close to fully pulling the handle in) but, the clutch slips like crazy under power.

    There seems to be no in between.

    I think the issue must be in my placement of the arm that attaches to the work gear at the clutch housing that the cable attaches to. Unfortunately all of the large clutch related threads are missing pictures.

    I’d appreciate any assistance. IMG_1732.jpeg IMG_1723.jpeg
     
  2. RiotFawk

    RiotFawk New Member

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    As an update/correction, it’s possible the metal plates weren’t installed correctly. After reading into it, it seems there is an inside and outside (though I’m pretty sure I didn’t change their orientation) and the tabs need to be arranged in some specific orientation (?). If only the posts that mention this still had the referenced images.
     

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