1985 XJ600 51J clutch issue

Hello all,

I have recenty started to rebuild my XJ 600 51j and I ran into an issue with my clutch. When I pull the handlebar lever it stays in the full pulled position and it doesnt return. I have bought a new clutch cable, and when I pulled the clutch cover off I saw that the release bearing is in pieces. The plates looked okay to me so as the clutch basket. I have replaced the release bearing, and the spring on the lever and I still have the same problem. Can anyone give me some pointers or something it would be much appreciated.

 

You should find the solution to your clutch problem here. Images are not available, anyone know how to fix it?

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

 

They're just gone.
There were some images that could be retrieved on some posts but the really old ones are generally vanished.

 

That's unfortunate .

 

do you have the return spring in position on top of the clutch release shaft, and when refitting the throw out arm, did you take up the slack first by rotating the shaft as far as it will go clockwise before fitting the arm?

 

I havent taken up the slack, will try that as soon as I can. Thank you all for help

 

I did everything even re routed the clutch cable in different ways and still have the same issue

 

Is the upper lever hard to pull? Does the upper lever feel fairly normal when you pull it taking a good bit of force as you should be compressing the clutch pressure plate springs when you pull the lever, which would mean you can adjust for 2 to 3 mm of free play?

The lever should stop as noted in this pic when pushed by hand:

 

the upper level is hard to pull and i feel it compressing the clutch plate and it also stops where you marked it, only when i pull it on the handlebar lever does it get stuck and not return

 

Managed to get a good feel on it and for the lever to spring back, but i cant shift higher than second gear. Any ideas?

 

Have you tried lubricating the cable? I had a Honda Nighthawk 750 that had a very hard pull to the clutch lever. I finally did a good clean and lube to the cable and that was the issue. There after it had the sweetest clutch of any cable clutch bikes I have had. After years of use the factory grease can harden or stiffen and really bind the cable. Simple and cheap if it works for you. Sorry but I have no ideas about your second gear issue.

 

I hope this is not your problem but you can check by following this. I would take the cover off behind the gear lever first and check for any broken springs as it is not stuck in first gear.

https://www.xjcd.org/emergency_guidectomy

 

Did some adjusting of the cable managed to get up to fourth gear, will try everything. Thank you for your help