Clutch trouble

Hey everyone,

So last time I posted it was about some carb issues which I’ve worked out and I’m happy to say the bike runs like a champ. Butttt I cannot figure out the clutch for the life of me now.

What it’s doing:

The PO put some terrible, cheap clip ons and attempted to reroute the clutch cable which didn’t work. So the clutch hasn’t worked since I bought it. I’ve replaced the bars with repro stock bars and run the cable every way possible and can’t seem to make it right. The push lever on top of the clutch seems to have decent tension but it’s pretty easy to push with one finger and it’s not strong enough to pull the loose cable closed.

What I’ve done:
replaced all the friction discs, plane discs and springs as best I could
Replaced the handlebars
Replaced the clutch cable

I’m really bad at explaining everything so hopefully someone knows what I’m talking about. I can take a video if anyone needs it and wants it.

 

What machine do you own? Is there an alignment mark on the clutch lever which should line up with a mark on the case? You should not be able to move the lever much with your finger. I need a spanner to move the lever on the clutch casing if I am changing the clutch cable.

 

There isn’t a mark that I’ve seen but I’m almost certain it’s in the right spot just going off of the clymer manual and other pictures of the bike. Should probably have mentioned mine is a 81 550 seca.

 

Alright so I’m tinkering with it and thinking I may have messed up the friction plates when I replaced them. When I remove the spring on the outside of the clutch it has no tension at all. Posting a picture of that now just to show what I’m talking about.

I’m assuming there needs to be tension on the clutch from the boss spring?

 

The spring hook at the end of the screwdriver has to go round the lever.

 

I had it around the lever. I just removed it to show it in the picture. When I took that spring off I was able to move the lever back and forth with no tension at all. Does that spring provide the only tension on the lever?

 

No the springs in the clutch create resistance to the lever. The lever should not be easy to move by hand. Think they may be something wrong inside the clutch cover.

 

Ok so I definitely have the friction plates on wrong. I went off the Clymer but I saw somewhere on the forum where someone said the illustration isn’t right. I tried finding the thread but I can’t seem to find it now.

 

Have a look at these.

https://xjbikes.com/forums/threads/clutches-101-part-1-the-400-550-600s-with-pics.29541/

 

CLUTCHES 101-Part 1: the 400/550/600s with pics

 

That is insanely helpful. Thank you so much.

 

If you follow the write up by Bigfitz, you should be alright

 

Just rebuilt the whole thing right after you sent that walk through and it was a breeze. Thank you guys.

 

Random,

This site is filled with very knowledgeable people, and useful advice and write ups.

Just ask and you will receive .......free of charge

 

Looking at your picture ,appears you a missing the bracket that hold clutch cable , at least I have this on my 750 Seca .