Clutch will NOT disengage

[cardboardguitar]

I just got an 82 xj1100, and I have everything on the bike working but the clutch. It's driving me a bit crazy

My clutch will not disengage whatsoever...

I read through all the threads on clutch problems similar to mine and have tried all the solutions suggested but none of it helped. I'm pretty much positive the problem is in the clutch basket... The cable, lever, and actuator all seem to be working just fine. I've adjusted it to spec multiple times and played with all the adjustments but it doesn't make a lick of difference.

I took the basket out and it all seems fine but i don't really know what I'm doing so who knows.

Any suggestions as to what would cause this, or where I should look first?

I just want to ride it so bad I can't sleep haha

[trbig]

When you took the basket out, did you seperate all the discs to make sure they weren't stuck together?

Tod

[cardboardguitar]

"did you seperate all the discs"

yeah i took them all out and inspected them to check that the friction material was good. it seemed to be fine...

[TopCatGr58]

Hey Cardboard,

In the tech tips, Mods if I remember, is the extra steel clutch plate, it has lots of photos to show the clutch process so you can review what you did.

Did you remember to put the larger diameter thrust washer down inside the clutch pack before you put the clutch boss assembly in the basket? Did you put the smaller diameter thrust washer on the clutch shaft prior to the basket?

Also, have you done the throwout arm slack adjustment at the engine case per the other maintainence tech tip??
T.C.

[Incubus]

Did you take the clutch apart because it would not disengage? Or did you take it apart to inspect everything and then it would not disengage after you put it back together?

Patrick

[DGXSER]

Like TC stated, if it were my bike, I'd get the parts diagram and pull that clutch basket out again. I would take some 220 sand paper to the friction disk and maybe 600 to the metal plates. measure them all if you did not already.

Then on reassembly look carefully at the diagram and make sure you got all the clips, washers, and sleeves in the correct spots, and that the pieces slide pretty smoothly into place. Would not be the first time that putting it back as it came out was just committing the same mistake the PO made. Also check that you got the basket to slide completely back. Couple of times I have noticed it not quite wanting to slide all the way back and fiddled with this or that to get it go.

[cardboardguitar]

Hey Cardboard,

In the tech tips, Mods if I remember, is the extra steel clutch plate, it has lots of photos to show the clutch process so you can review what you did.

Did you remember to put the larger diameter thrust washer down inside the clutch pack before you put the clutch boss assembly in the basket? Did you put the smaller diameter thrust washer on the clutch shaft prior to the basket?

Also, have you done the throwout arm slack adjustment at the engine case per the other maintainence tech tip??
T.C.

I haven't checked out the extra steel mods no, but isn't that to solve a slippage problem?

As for the washers, I know I put everything back the way I took it off but its entirely possible it wasn't in there correct to begin with, so... I think I will take it apart again, diagram in hand and check on that. thanks

And yes I did the throwout adjustment. all the way in, quarter turn out, etc... and then i messed with every increment I could but nothing helped

[cardboardguitar]

Did you take the clutch apart because it would not disengage? Or did you take it apart to inspect everything and then it would not disengage after you put it back together?

Patrick

I took it apart because it would not disengage. AFTER doing every adjustment I could...
Its behaving exactly how it did before I took it apart...

[cardboardguitar]

Like TC stated, if it were my bike, I'd get the parts diagram and pull that clutch basket out again. I would take some 220 sand paper to the friction disk and maybe 600 to the metal plates. measure them all if you did not already.

Then on reassembly look carefully at the diagram and make sure you got all the clips, washers, and sleeves in the correct spots, and that the pieces slide pretty smoothly into place. Would not be the first time that putting it back as it came out was just committing the same mistake the PO made. Also check that you got the basket to slide completely back. Couple of times I have noticed it not quite wanting to slide all the way back and fiddled with this or that to get it go.

That all sounds like good advice, I will try all of that, Especially checking how the basket is seated, i'm pretty sure the problem isn't in the plates themselves but I'm no expert so I'll be sure to try all that advice...

[Ivan]

On the inside of the cover, there sould be a piece with three steel balls in it, have those balls fallen out? If you adjusted the screw right and the cable is actually pulling the lever, then the only thing that makes sense is that the balls aren't there, and it isn't pushing the throw out bearing since they aren't rolling on the ramps.

[cardboardguitar]

On the inside of the cover, there sould be a piece with three steel balls in it, have those balls fallen out? If you adjusted the screw right and the cable is actually pulling the lever, then the only thing that makes sense is that the balls aren't there, and it isn't pushing the throw out bearing since they aren't rolling on the ramps.

no i've thoroughly checked all that, the whole lever mechanism seems to be working perfectly, the balls are all seated properly, and push out when the lever moves up.. and there doesn't appear to be any excess wear or anything... I'm pretty much positive the problem lies in the clutch itself somewhere...

[jrplumber1]

You said it!!

You said you turned it all the way in?
You only turn the screw till lightly touching the throwout berring then back off an eighth of a turn.
If you turned it all the way in it is holding the cluch pack open.

[Incubus]

Are you getting resistance at the clutch lever and the clutch is just not working, or is there no pressure at the lever and it feels slack?

[cardboardguitar]

You said you turned it all the way in?
You only turn the screw till lightly touching the throwout berring then back off an eighth of a turn.
If you turned it all the way in it is holding the cluch pack open.

i started by screwing it in until i felt the resistance of it just touching, then backed it out a 1/4 turn per the service manual instructions, but after that not working, I tried it at every possible interval from all the way in to all the way out, and everything in between, no effect

[cardboardguitar]

Are you getting resistance at the clutch lever and the clutch is just not working, or is there no pressure at the lever and it feels slack?

I'm getting full resistance with no slack after adjustments, but it has no effect on the clutch actually working, when i squeeze the handle the lever goes all the way up, the throw rod/bearing assembly pushes out, but the clutch doesn't release. so if I attempt to shift from neutral to first it just kills it. pulling or releasing the clutch has no effect... which is why i suspect the problem lies in the clutch assembly/basket itself... actually, even after i remove the star plate which normally holds the springs, and the clutch plates are all hanging loose in the basket with no tension on them, and I shift into first, it still acts as though the clutch is engaged. so perhaps the problem lies somewhere in between the gear and the basket? I'm not exactly sure how its supposed to behave because this is my first bike, and the transmissions on bikes are so different from the cars I'm used to working on...