FJ600 Very Short Friction Zone

The friction zone on my FJ600 is extremely short/narrow. I adjusted it at the case and the lever but it still doesn't have much of a friction zone. It is more like a toggle switch. The bike/clutch only has 11,000 miles on it. Bad friction plates?

Any help is always appreciated

 

Search for RickCoMatic's tech write-up on adjusting the whole cable.

Any chance you routed it wrong ?? Lubed recently ??

 

I thoroughly lubed the cable and routed it per the factory manual. It operates smoothly, no binding and it has plenty of throw. Just a really minuscule friction zone. Pull in the lever a smidgen and it releases 100%. Is something going on inside the case?
Thanks
TR

 

Do you have some free play? At the case too? If so, your issue will be internal.

 

New friction plates?

 

Quite possibly.

If it's the original clutch, it's what, 29 years old? Mileage has nothing to do with it, if it's that old it's pretty much all done.

When the bike sat (and it had to have or it would have way more miles on it) the oil-soaked friction pads dried out and became little bits of hard linoleum. It doesn't matter if they're worn or not; they're not made of friction material any more. Now that you're putting them through heat cycles again, they've become even more petrified.

New friction plates, clean up the plain plates with Scotchbrite and reuse as long as not warped or burnt, new springs and bolts and a gasket and you'll be all set.

http://www.xjbikes.com/forums/index...-101-part-1-the-400-550-600s-with-pics.29541/

 

Yes, I suspected the friction plates. Sounds like a winter project was just added to the list.
Thanks
Tom

 

Read my how-to. It's a 3-hour job, max.

If you really want to put it off, be careful of signs of slipping. If you ride it with it slipping, you can end up costing yourself a set of new plain plates.

 

take a look at the lever. the hole that the pivot bolt goes through can get worn to a oval. this messes up the whole geometry thing.
even if yours is still ok it's a good idea to to clean the perch out and put some new grease on that stuff

 

Yep, I did lube the mechanism and checked the pin when I put the bike back together.
Thanks for the help
Tom