XJ 650 TURBO STARTER CLUTCH

Can anyone help the bike won't start and it is the starter clutch that has gone, have a repair kit but not sure of the best way of fixing the clutch.

Am I correct that the engine will need to come out and be split?
Also new full gasket set will be needed.

Has anyone got any advice which could help sort this problem.

Thanks for your time guys. :wink:

 

The absolutely last thing that I would be wanting to get is a set of caskets!!

 

You just need one BIG casket - -

You will need to split the case, or do like member "Wizard" did and carve a hole under the carbs somewhere for "easy-access".

(yes, this really happened!! I hear those Brits are a bit stubborn)

an extensive debate on the subject here :roll:

 

CASKET?!?!
Reminds me of that guy from Ohio that was buried with his H-D last winter. Now that was a BIG casket.

 

can we get to the starter clutch by removing the engine from the front and taking the sump off (local mechanic asks).

 

You can't access it from the sump,

split the cases on the workbench.

Buy a new chain-guide while it's apart.

 

a stitch in time..... before you get started, are you sure , as in absolutely sure, that it has the rite oil inside, ... not the you beut slippery stuff that stops starter clutches doing their job???

 

Oil is correct

 

O.K. How is it going?

 

Can someone post details on one of our starter clutches.They seem to be shroulded in secrecy , even as to where they are located , & what is actually inside them ,.Thanks guys, and thanks CHACAL for that bit about the hidden jewel. Did not get a mention in the Haynes C.D. Worked like in a dream ..

 

There's no mystery, you just haven't gone looking in the right places to see. The starter clutch is on the same shaft as the alternator, but on the right side of the case, and is inaccessible without splitting the cases.

Pics in this gallery: http://www.xjbikes.com/coppermine/cat=16384.html

If you decide that you have to R&R the starter clutch you will NEED to have a copy of the factory service manual AND a copy of the Haynes manual in order to get the whole story of how the job is done. Read, read, read and visualize yourself doing the job before you tear in to it. Plan on spending two full weekends, at a minimum if you haven't pulled a motorcycle engine apart before. The job isself isn't complex, but it is time consuming and there are some fiddly procedures involved in getting everything lined back up when you go to put it all together again.

Senzei,

I'm not doubting you when you say the oil you are using is correct, but I do want to verify that it is a JASO MA certified oil (or the equivalent).

I'd also like to know if you have inspected the internals of the starter motor recently. A sick starter will mimic the symptoms of a faulty starter clutch.

 

Hi Guys the bike has stripped just got to remove oil and take the engine out split and hopefully sort out, this will be done on Wednesday, have a guy who works on bikes helping. Thanks for the feedback and the pics, the bike for a while had not been to happy when trying to start, start button hit and would take a bit for it to catch the start, when it did not catch it would make a horrible chain sound. Now she won't catch at all so engine won't start at all.

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That would definately be the starter clutch failing. Get a primary chain guide while you're at it. They tend to break apart after a few decades. It's worth your while to put a new one in while the case is open. And since you will have the starter motor off, get a rebuild kit for it too. Use the down time to get a many things up to snuff as possible.

 

Hi again must say the information given is top notch thanks all.

OK so many different engine oils but which one does anyone rate better?

Also a Starter Chain any ideas of where this can be brought (been told to change it) and a chain guide.

Thanks just hope that all goes ok on Wednesday

 

XJ CUT AWAY
S/C
S/C

 

Hey Wiz - you still have the pics of your "access hole" , or did you leave them in OZ ??

 

How could I erase that from my memory.
STARTER CLUTCH

 

While unplugging and disconnecting cables pipes etc one of the pipe has broken it, has anyone got any idea how to sort. What pipe is damaged?
Could it be replaced? Thanks
Also the guy who is helping dropped the engine and around 3 of the engine fins got broke, can anything be done about them? if you understand what i mean?
Engine now out and what a job, just hope it goes back easier.
Any tips on the reinstall let me know.

 

last time i put a engine back in, i unbolted the swing arm and pushed it back a inch or so and held it there with some sticks of wood. just the two pivot bolts not the shocks and wheel. things went much smoother.

 

That's the oil feed for the Turbo. You'll need to source a replacement.

The "bolt" that you are holding in the first picture contains a check valve. If you can source another one of these to have on hand that's good to. It keeps oil from filling the turbo when the bike is off.

 

So, have split the engine cases and removed the gear box components. Is there an alternatetive way of removing the rotor to release the starter clutch shaft ? If not do we need a special tool and where are they available from ?

 

On fin repair -
You need to have the broken pieces, or get more from an unwanted engine.
Get some "aluminium soldering rods" off the internet.
grind things smooth and paint 'em black.

 

About the manuals:

1. Has there never been Haynes manual for T11? Will manual for XJ 650 and 750 Fours do the magic despite of the fact that block differs from non-turbo models (before I send it back to eBay seller, because it was sold as a manual for T11)?
2. Factory service manual? I have Yamaha XJ650T Supplementary manual. I think it is quite high level manual, so is there manual for professional workshops?

 

The supplementary manual covers the differences that are not covered in the service manual. The turbo engine cases are not much (if any) different from the non-turbo cases (Yamaha did not build an entirely new engine for the turbo bike). You want the manual that was intended for a technician, since you will be doing the work that a tech would be expected to do.

 

I wonder if the manual for technicians is that kind of collectible and rare, that there are not available any originals?

In eBay there is available at least three kind of manuals:
- Yamaha Supplementary Assembly Manual 1983 XJ650 LK Seca
- Yamaha Factory Service Manuals XJ650G and XJ650LJ Turbo
- Yamaha Xj650 Turbo Service Guide Manual

The second one is the one that might be correct?

Unfortunate thing is, that the manual is a bad copy of the original, price is already high and there will be additional shipping cost and VAT's.

It would be nice to have right one and not to collect them all.

 

I can see that link to coppermine pictures is outdated. Has the pictures moved to somewhere or aren't they available anymore?