Be carefull with clutch star

[Tusler]

Hi,
Well I got all the stuff in the mail so today I dived into the clutch. Well as I pulled off the cover I see the star (pressure Plate) was broken on one of the tangs. I took the rest apart to check and see if the PO had messed anything else up. After flattining the lock washer on the nut it took me over 200 Ft Lbs of torque to break it free!!! The good news is all the plates are in excellent shape. I called a couple of Shops and was told that not only is the star plate out of production but no other bikes use the same one as the XS1100. I found a complete clutch assy for $68 shipped on Ebay so I ordered it quick. Just a warning- don't break the star I guess there are very few left.
I wonder if anyone has started machining them out of steel yet !

[prometheus578]

Yeah, there's been several threads over the years dealing with broken star plates.

[mro]

I found a complete clutch assy

Now you can do the "extra steel plate" mod too.


mro

[barberad]

I've got a question on the extra steel. All the things I've read on it. TC never say's where to put the extra plate. suggestons? and would you got from 40 wieght to 50 waight oil after doing this? or is the great oil conundrum just personal choice? I followed that thread on oil forr about eight pages and I'm still uncertain as to which is better in relation to the clutch.

[psycoreefer]

Well if you break that one PM me, I've got an extra.

[trbig]

Don't worry about changing your oil preference or weight. The location of the extra steel isn't of major concern, but most put it in the middle.

This is just one of those "Throw it in and go" things. You can even do it without even draining your oil. Just put the bike on the sidestand.

Tod

[andreashweiss]

ebay price inflation

I do not reply often , but this post I am forced too. People you are paying to much for these parts on e-bay, I have several clutches in the parts pile, They are sold complete in the basket with every part, basket,springs,plates,star, etc price of $50 includes shipping in continental USA by priority mail , used parts, clutch may be worn , but no visible damaage but certainly plenty of parts for a decent price, thanx andreas

[Tusler]

Extra steel plate mod - Done. I also checked the friction rings and they are all almost new. Oh yea, this thing will not slip when I get done with it. Might have to replace the cable more often, but it will not slip.
Is there a reason the star was not made of steel, or is there a reason I should not have a machine shop make me one out of steel and then press the bearing assy into it?

[TopCatGr58]

Hey Tusler,

Well, I would think the weight would be a factor, but perhaps not much of one? Cars use steel pressure plates and assemblies.

GO for it, and let US know what the shop charges, or what the final price is, you might have something to sell? Andreas has some for now, but could be a good thing for in the future?
T.C.

[Tusler]

Reman of Clutch Star assy. is in work

I found a machine/welding shop who likes bikes to take on the job.
The condition of the finished produce that we are shooting for is
1. made from steel.
2. unbreakable by spring misplacement.
3. make spring misplacement impossible.
4. stay close to original weight spec's.
5.work perfect for the task.
6. be able to guarantee for life of bike.

The original prototype is going to cost $150

If it meets all the criteria I have set then I will go into sell them.
Once production starts if we get enough orders the price will come way down.

[webbcraft2150]

When you attack a project on one of these rigs, do a search or check the tech tips. If that fails, ask up. There will be plenty of people to tell ya the pitfalls of any given project done on a XS11. Now that said, watch out if you remove the cam chain tensioner, you do not have to remove the driveshaft to get the front boot on, fork seals are easy with the homemade tool, make dam sure the fill plugs for the middle and final drive will come out before draining them and do not submerse your carb bodies in Berrymans!!!

[Tusler]

Star Install Procedure

I finished modding my clutch and have a big tip.
First if you have problems finding the Lock Washer called for in the XS1100 parts you can substitute 90215-20231-00 and it works perfect. It is not in any cross references.
Second when you put the star (pressure plate) on take all the springs out and by hand make sure the star will slide all the way in without grabbing or hanging up.
Then put the springs,star and bolts on carefully lining up the springs. What worked very well for me is using only my hands with a socket and extension turn the bolts in 1/2 turn at a time working back and forth across the star so all bolts are going down even. When you begin to feel things get tight by hand use a rawhide, rubber or plastic mallet and lightly tap around the star, you will find the bolts turn easy again, what this does is help line up the star and slide it into the housing. When the bolts are snug by hand and tapping does not make a difference then torque them down and you are almost ready to ride.