Clutch Headache.

Okay my xj1100 is almost ready. All I have is to fix the clutch.

What it used to do was when I got it on the highway and really kicked the throttle the rpms would jump to 7000 and then the bike would catch up. Bad slippage.

So in all my wisdom I picked up some clutch springs (OEM) and put them in. Now my clutch slips all the time. Even off of the start in first gear. My rpms go up but my bike slowly moves. The clutch is always slipping.

I have a spare clutch from my backup bike. I put the spring on it an tried it as well. The exact same results.

I checked my clutch cable down by the engine where it connects to the lever and it is not tight at all. I can wiggle it with my finger and there is no tension when the clutch is not engaged.

Any ideas at all.

Many thanks in advanced.

Dave...

 

Oh ya I thought I would add that I have the big washer on, then that collar thing (spacer I think we call it) Then the primary drive gear comp., then a small washer, then the washer with the tabs that you bend up to help lock it (torqued to 50 ft lbs) then the clutch basket with all the plates and stuff, then the springs, with the star shaped plate bolted on tight. Next comes the clutch cover with the clutch push screw assembly, this connects to the cable (once again the cable was not tight, I could move it with my fingers). Then the final cover plate.

So where did I go wrong.

 

One last thing. It is an xj1100 and I am using Rotella T oil

 

Is there any free play in the clutch linkage? The cable can be loose but the lever it hooks to should also have some freeplay in it also. Its the screw and nut in the center of the clutch cover.

 

Adjust the Knurl on the Perch to "Half-way"

Make the Cable adjustment at the Bracket on the Case.
Slack the Lock-nuts.
Disconnect the Cable from the Throw-Out ARM.

Rotate the Clutch Throw-Out ROD going down into the Clutch to the RIGHT removing ALL play.
(Wrap a leather shoelace around it like starting an old mower and pull it tight Clockwise. Tape the lace down when the ROD is fully taunt.)

Remove the Throw-Out ARM from the ROD and position the ARM on the ROD where it will attach to the ROD with the Cable installed and be TAUNT.

Affix the Lever to the ROD
Pull the Cable Tight and secure the Lock Nuts.
Feel the Cable.
Adjust the Cable End-barrel to remove ALL slack.
Tighten all the adjustments.
Remove the item securing the ROD.

Loosen the Cable Adjuster AT THE PERCH and take-up the Cable Slack so there is ZERO LASH.
The Cable has slack and Throw-Out arm "Clicks" with freeplay, ...
and a bit tighter and there is NO click.

Lock it up.

 

All is well now. I took it apart double checked everything, put it back togeather, adjusted my clutch at the engine and at the lever.

All is well.

Thanks for all your help.

 

did u think to check the spring on the lever that goes into the motor. sometimes they take a shit. or ur clutch plates could just b that shot in both bikes