Clutch issue(s) MaximX

1985 Yamaha XJ700X-Maxim non CA model with approx. 18,000 miles. Mostly freeway ridden, especially the past 2 years where 13,XXX of the miles have put on. Second owner, and I know the original owner.

Bike had sat for 7-8 months while I was in Alaska. I returned, bought a new battery, replaced the fork seals, drained the fuel (which I had put Sta-bil in before leaving), fired it up and went for test ride. Clutch did not feel right, tried to adjust cable ended up removing, lubing, reinstalling and adjusting cable. ☆Note: Clutch cable had been replaced the year before.
Still didn't feel right, tried it anyway. Cannot select Neutral at a standing stop while engine is running, in first gear it still wants to pull even when lever is fully pulled in. When I say fully pulled in, I can only get about half or little over half pull, then it will not go any further. I know the symptoms sound like the typical out of adjustment, but I have tried adjusting it multiple times.
Thinking it maybe in the clutch itself, I removed the cover and the clutch pack; inspected each component, reinstalled and had the same result. I did this two more times with friends that are knowledgeable about motorcycle clutches and they are puzzled as to why it will not fully engage the clutch.
Anybody have any ideas, I will be happy to try them out with bells on and dancing the jig especially if it solves this issue!
Thanks in advance and apologies for the long post, just wanted to give as much info as I could think of.

Gary

 

First thing that comes to mind is the lever on clutch case. Is it indexed correctly ( small notch on arm pic #1)to the raised marker on case( pic #2) this can be all out of whack if you turned the lever with cover off and little pressure bolt with teeth on it was reinstalled wrong. As long as mark on case and mark on lever arm line up it should work.

 

go to this link and do 4 more posts so you can post photos
Test Zone

then post photo of clutch perch and lever on the motor

 

when you replaced the clutch how tight did you make the screws (with the springs on them) holding the clutch pack together?
Sounds like you tightened them too far.

 

Do you have a manual? This has the torque specs and step by step how clutch is assembled. If you had it apart was there any blueing of the plates? ( indicates slipping and burning )What did the clutch plates look like ? If you had it down did you replace clutch plates?

 

Negative on the manual. Ordering one tonight. Clutch plates and clutch disks look great, no signs of any abnormal wear, over heating, I didn't mic them, but they looked as if they had plenty of life left. The plates still had dimples on them as well. No scarring, blueing, etc.
I'm hoping that I over tightened the springs, but are they prone to tightening themselves as the symptoms are the same as before I got my paws in the mix?

Thanks for the replies, will update with any results.

 

Oh yeah, it sure sounds like I did... they are WAY more than 5.8ft lbs! Will tear back into it tomorrow and go from there.

Thanks again!

 

Only thing that happens if they're too tight is you break the bolts.
My money is still the arm on the case is not lined up correctly. Remove the clip and rotate it to align properly. Post a pic of it .