Instruction on how to reinstall shift shaft?

I removed the shift shaft on my xj550/yx600 to install an updated shift pawl. I’ve reinstalled it twice now, but every time it won’t change gears after I tighten the clutch cover back on.

My service manual doesn’t cover the install and I haven’t been able to find any videos of this specific bike.

Does anyone know where I can find a step-by-step instruction so I can figure out what I’m doing wrong?

Thanks in advance!

 

Manual here. What manual do you have, Haynes?

https://www.xjcd.org/index.php/service-manuals

 

I was looking here did not see it. Does your bike have an adjustable clutch pushrod? Might be your issue if is has.

https://www.xjcd.org/index.php/node/1261

 

https://www.xjcd.org/index.php/node/1287

 

It does have the adjustable pushrod. Maybe I didn’t line up the lever properly. I’m going to take it apart again tomorrow.
Thanks!

 

I don't have a 550 but if you had the lever the clutch cable attaches to on the clutch cover thar could be misaligned or the adjuster not right or both.

 

Here’s what my steps were last time (maybe you’ll see an error):

1) I removed the foot shift lever , then the sprocket cover from the left side of the bike.
2) removed the clutch cover, clutch assembly, basket (etc) to get to the shift shaft. Then removed the shift shaft from the bike.
3) I disassembled the shift shaft to install the R6 shift pawl and associated spacing washers. (Purchased from Len for my yx600/xj550)
4) I reinstalled the shift shaft and ensured that it changed gears. I went through all gears until I found neutral. I found that all gears except neutral wanted to push the shift shaft to the right side of the bike.
5) reinstalled the clutch and all components. I wasn’t able to properly torque the clutch boss nut because I didn’t have a “clutch holder tool” (I do have one on the way now though). To tighten I used my Milwaukee mid torque impact on setting 2.
6) put the clutch cover back on and torqued all fasteners properly.

I’m still suspecting the clutch lever as I never detached it from the clutch cover. I know it engaged but maybe it doesn’t have proper range of tension / movement (if that makes sense.)

 

Mabe the lever position out. Look at this thread.

https://xjbikes.com/forums/threads/clutches-101-part-1-the-400-550-600s-with-pics.29541/

 

Very helpful. Thank you. I believe I did everything right EXCEPT the alignment of the lever .

I hope to check it out today.

 

There is a dot on the lever of my 900f to help with correct alignment of the lever.

 

https://xjbikes.com/forums/threads/83-550-maxim-clutch-adjustment.40513/

 

I had a chance to take the clutch apart and reinstall it properly today. I bought a clutch holder tool so I was able to torque everything properly. I also took your advice and removed the shift lever from the clutch cover. This allowed me to precisely align it once the cover was on. Everything feels great.
I still need to install my new rear tire so I haven’t tested things out yet, but I don’t expect any issues.

Thanks for your help!