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sticky clutch

Discussion in 'XJ Technical Chat' started by Groundswell17, May 17, 2012.

  1. Groundswell17

    Groundswell17 Member

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    Hey guys, it wasn't long ago a rebuilt my clutch. Since then i've noticed my clutch is actually sticking, hard to shift, and only disengages when i twist the throttle to break it free.

    I have aftermarket control levers, but seem to give the same amount of play. I adjusted the throw arm to the notch as recommended, and tightened the cable just to where it's snug. any ideas? (new springs new friction plates, plain plates looked great)

    it's to the point where twice now, i pulled up to a redlight with the clutch engaged (i mean lever engaged, clutch disengaged) , and as i came to a stop, so did my motor, haha. When i went to quickly restart it, the bike tried to lunge forward a bit, till me holding the brakes broke the clutch free.

    i may try and tighten it some more (the cable) or set the throw arm one notch back so it gets a little more range of motion, but i'm concerned the clutch won't fully engage if i do this, making me burn through both the friction and plain plates.
     
  2. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    Did you line up the dot on the pressure plate with the dot cast into the hub? Failure to do so can cause a sticky clutch.

    PLAY is not going to be the issue if the problem is the aftermarket levers; THROW is a potential problem, in other words, does the lever produce the same amount of "linear pull" on the cable that the originals did?
     
  3. Groundswell17

    Groundswell17 Member

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    yes to the dot on the cast to dot on the hub,

    throw is what i meant by play. the lever has the same amount of movement (play) as the stock. it's obviously a guess, unless i hook a cable up to both and see how far the cables can be manipulated. But when i got them i put them side by side and and they each have the same range of motion.
     
  4. mlew

    mlew Well-Known Member

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    I am having the same problem on my Venture. The friction plates and steel plates are sticking together. Both sets are new. It is a pain, makes it hard to shift . When the bike sits for a couple of hours you better hold the brake when starting, it will move forward.
    Don't know what is causing it but I would like to find out.
     
  5. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    Weird.

    What oil (for both of you?)
     
  6. Polock

    Polock Well-Known Member

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    on your clutch basket, in the slots that the friction plate tabs fit into, there gets to be ridges that the friction plates can get hung up on.
    the lever releases the pressure on the plates but the tabs on the friction plates get stuck on the ridges. you can carefully file the ridges down and make it work again
     
  7. MiCarl

    MiCarl Active Member

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    I was inside a V-max recently to replace the shift sector. Reading the clutch assembly instructions it talks about orienting the cut outs in the friction plate tabs a certain way. It goes on to say if it doesn't operate smoothly to change the orientation.

    I'm 98% certain the Venture will be the same. Might be something similar with the XJ, but not certain.
     
  8. mlew

    mlew Well-Known Member

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    I'm running Castrol 20-50 morotcycle oil. Friction(EBC) and steel plates(OEM Yamaha) are new. The clutch drum and basket have no groves worn in them, plates slide on them with ease. Last time I had the cover off I pulled the clutch and could see the pressure plate release with plenty of room for the plates to move. I took the pressure plate off and could pull most of the friction and steel plates in one chunk. A light tap and they would seperate, They are definetly sticking together and not to the drum. Yes the plates marke are ligned up witth the markes . Everything is assenbled as the manual shows.
    Yes MiCarl the Venture and V-Max clutch is almost identical, pressure plate is the only difference. My V-max shifts smooth, Venture not so much. Any insight would be helpful, seems others are having similar problems.
     
  9. Groundswell17

    Groundswell17 Member

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    i'm on penzoil 20-50 for motorcycles, non synthetic.

    there is no special way to put in the friction and plain plates on my bike, just pile them on up in there, but i can't say i thought about the ridges that polock mentions, nor did i check for them. I'll try and get in there tomorrow and see how it is. I completely overlooked that when i replaced the clutch. it's a possibility that the tabs on the old friction plates were a little worn and did not have such sharp angles that could catch, while the new ones maybe have straight edges that are getting hung up in any ridges or grooves.
     
  10. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    Check both the hub and basket ears for "divots" from the plates.

    There will be "polished" spots, but if they've formed actual pockets the plates will hang up. You can use a small stone or fine sharp file to smooth out minor dips, but if it requires removing very much metal it's better to replace the parts. Finding clutch parts on eBay is easy because of the commonality, just be sure it's from a lower-mileage bike than yours.

    How many miles on your Seca?
     
  11. mlew

    mlew Well-Known Member

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    Any ideas on why my plates stick together? I have tried sever brands of motorcycle oil and Rotella HD , same results with each. Might try car oil and see what happens.
     
  12. Groundswell17

    Groundswell17 Member

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    i'm not sure about miles, speedo said 16k when i got it, but it was all messed up, no speedo cable :p

    mlew, i have noo idea, lol. i'm in the only one in here without the xj wizard branded to me. but i thought car oil was a big no no. i'de say double check for wear before you do that, only other thing i can think of... the clutch plates. mine were made in taiwan, can't remember brand right now, where are yours out of? could be the outcropped metal edges are a little over tolerance, causing some catching. gonna try and get out there now after i get some other stuff done, take a look at this thing
     
  13. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    Could it be related to:

    I read this in a service manual recently too; I believe it was for the "X" series XJs (but I'm not sure,) however it might apply in your situation.

    In what I read, it indicated that one of the "gates" (spaces between the "ears") in the clutch basket is narrower than the others, and that the friction plate tab with the "V" notch has to go in that narrower spot. It also said that if the "indicator" mark was not visible on the basket that it might be necessary to measure the tab slots on the basket to find the oddball narrow one.

    Note*** THIS ADVICE DOES NOT APPLY to the aircooled XJs; I read it in another Yamaha manual.***
     
  14. mlew

    mlew Well-Known Member

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    I have EBC plates now, can't say anything bad about them because some of my other bikes have them also. I can't blame the plates because it did the same thing with the old ones . New steel plates helped a little but not much. I have checked the drum and basket so mant times I have a picture burned into my brain snd I can't see anything wrong. It looks and feels just like the V-Max which shifts great. I probably won't do anyting else on it till fall/winter, just want to ride now.
     
  15. moellear

    moellear Member

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    did anyone get anywhere on this??

    I have had similar issues, and I'm in the process of trying to eliminate speculations. Just researching right now so thought I'd ask!
     

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