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XJ650 Clutch Replacement

Discussion in 'XJ DIY How-To Videos' started by taptapindustries, Nov 27, 2017.

  1. taptapindustries

    taptapindustries New Member

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    XJ650 Clutch Replacement. New Friction Plates and Springs.
     
  2. Pizzaman

    Pizzaman New Member

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    Saw this the other day on YouTube. Is it really that easy? Clutch is fine right now on my bike but it is 35 years old so I'm assuming someday it will have to be replaced.
     
  3. Toomanybikes

    Toomanybikes Well-Known Member

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    Someday maybe. The hardest part of the job is scraping off the old gasket.
    Last summer my 6 year old grandson did a re&re of a clutch in an fz750. Just told him how to do it and the only thing I did was torque the bolts on the pressure plate.
    My xj650rjc has the original clutch and I have 50,000k on it and still works perfectly. As long as it hasn't been beat on it can last for another 50k with good oil and properly adjusted . I can still pull 9,000 rpm in top gear with no signs of slippage.
     
  4. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    - CLUTCH REBUILDING ISSUES:

    The rebuild process for most clutches is pretty straightforward; although this thread is specific for the XJ550 models, the same basic steps and parts also apply to all the XJ550 - XJ1100 models:

    http://xjbikes.com/forums/index.php?threads/29541

    Please note that while the above guide is specific for the XJ550 clutches, all XJ-series bikes use the same basic procedures as above, with a few minor differences in drive plate style and design.

    And here’s a good introductory video on doing a basic clutch rebuild (the video at the top of this page):



    Here are a couple of additional do’s-and-don’ts that we would recommend:
    - always check the metal drive plates for flatness using a feeler gauge and flat piece of glass, etc.
    - align the throw-out gear teeth towards the SW corner.
    - always use new pressure plate spring bolts!
    - perform the final torque on the spring bolts in criss-cross ("star") pattern.
    - use a proper cover gasket rather than sealant!
     

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