Clutch prep checklist?

So my list is getting shorter of things to do.

I'm pretty sure my clutch is on it's way to toast from the PO

It runs great for how I ride it actually. But when I hit that country road and feel like giving it a lil goose I find that around 6500 on the tach then it suddenly wants to slip gear on me.

If I'm in top gear it will hold for longer, to around 90-95 depending on how smooth the road is.

On a normal ride, I never hit 6k so I don't normally notice it. So many country roads.

Anywho...

I'm pretty sure that's clutch.
So first question.... That's the clutch right?

Second... So that means clutch plates, should do springs since I got it apart, Oil, filter since it's drained, manual says to get a new clutch boss lockwasher....
And what else should I get before hand..... Thrust plates? Oil seals? Snap ring cause the lil bugger just won't come out without a little aggression? Metal plates cause it's a good idea since I"m doing it and they're cheap??

After that
Last question
any other recommendations? horror stories or warnings?

Thanks!!
koi

 

It depends on what you mean by "slips gear." If you mean the bike is still in gear, but the motor revs up without a corresponding increase in acceleration, then yes, it sounds like the clutch. At that mileage, if original, it's clutch time.

A basic rebuild would be the friction plates, new springs, and a cover gasket. You don't need to replace the oil seal in the cover unless it's leaking. You don't necessarily need to replace the plain plates; inspection will tell you that. You shouldn't need a tab washer for the clutch hub nut since you should have no reason to remove the hub.

The clutch on your bike is virtually the same as on the earlier XJs; the basics are covered here: http://xjbikes.com/Forums/viewtopic/t=29541.html Some of this won't apply to your bike, for instance you won't have to worry about tabs on the plain plates. Everything else is pretty much the same; it looks the same in there, and this will tell you what to expect/look for.

 

Don't dive-into this Clutch-job, ... "Blind"
GET ~ A ~ WORKSHOP ~ MANUAL.

Take your time and follow the outlined procedures and you'll be back in business motoring-along with a NEW Clutch.

It's well worth the dough to pick-up a Workshop Manual to guide you.

 

I've got a manual, I was just wondering what parts I should buy before tearing it down....

I'm not going into it blind per say, just dont' want to have to wait on parts for 3 days if I can order them now, ya know?

 

After seeing some of the illustrations from the manual I am starting to realize that its probably best to find 99% of your information and techniques on xjbikes. The manual is great for somethings I guess AND bragging rights.

LOVE LOVE LOVE Bigfitzs write up on Clutch work and picking his brain as we speak.

 

i failed to replace my springs when i replaced my disks and that was a regret. it slipped while accelerating hard. i replaced the springs and it works great BUT while getting ready to torque spring bolts one snapped off!!! they only get about 6lbs of torque and i didnt even get it torqued to that before it snapped!!!!! whatever you do replace the spring bolts because they are cheap to replace but a pain in the butt to drill out without messing threads up. i would replace the springs and bolts for sure! good luck!

 

That's good advice, especially if they're not the proper "factory" bolts with the flanged heads, and you also need the proper plate washers that go between them and the springs. Hardware-store stuff doesn't cut it.