550 clutch,trans issues,rebuild clutch,still stalls

Help lol it's 10' up here and propane is expensive

 

OK. The others may not have read your original question, so add some detail.

My first question to you is, what made you decide to put in a new clutch? Be as detailed and specific as you can. I'm not convinced that the clutch is the root of your problem, but we need to know more.

 

does it stall when you put it in gear?

is your sidestand down when you put it in gear? another safety switch

lift seat at rear of tool tray near fender is a cube relay remove it it disables the sidestand safety switch

 

I do also still have concerns about the differences you mentioned in the clutch you were sold. Just bcause you got it from a dealer does not preclude it from being the wrong part. BTDT, have the parts sitting on my shelf.

 

Welcome to winter.

Let these guys give you some solid advice and wait for some slightly warmer temperatures to move in. More often than not it is best to go slowly with the troubleshooting process. Being in a hurry can create headaches.

 

Here's the whole story,got the bike from a neighbor.had been sitting for years ,bought a battery,cleaned carbs and tank.new plugs .started runs great ,put in gear and stalled.so took clutch apart cleaned it up ,did not have boss spring ,or special friction plate.bought boss spring and new gadget.put it back together with the help of clutch 101 on you site .back to stall when I put in gear

 

that is your sidestand safety switch remove the relay and see if the problem goes away. your bike thinks the sidestand is down when you put it in gear

 

Yep. You have an electrical issue, not a clutch issue.
Also pop the rubber boot off of the swich and give the switch a good cleaning with contact cleaner to get rid of the grime that's making it sitck.

And check the valve clearances. It's not a part of your problem, but has likely never been done.

 

I concur with doctors Kmoe and Xj550, the symptoms are just what my 550 does when sidestand switch is sticking.

 

You guys rock !!,just took the xj 550 for a rip ,kinda like snowmobileing without snow ,9' here had a blast .it was that relay for the kickstand .going to paint tank and exhaust,black out!!

 

The relay is probably fine. Did you clean the switch and check for broken wires or corroded terminals?

 

as Kmoe said you should check the switch and connectors out . clean or replace if needed.
the removal of the relay is just a test for the sidestand safety switch being bad.