xj clutch question

[xj11DAN]

I have recently been replacing my clutch and i have not been having a very succesful run at this thing. I have new pads, cable and thrust washer. when looking at the manual today i noticed a washer that i do not have in my bike. i am thinking this is the problem??? i guess the best way to describe it is that in the center of the basket is the shaft, behind the basket is a washer then a sleeve, inside the basket is another washer, the clutch boss and the lock washer and nut, the star plate and then the outer spring bolts. any idea if the back washer is in the xj or not? i have a n xs manual. yamaha says it is the same clutch assembly. hopefully some one knows. I do not think the clutch has been into previously, it only had 6 k on it when we got it.

[TopCatGr58]

Hey there XJ11Dan,

Just checked the Yamaha Online Parts Fiche for the XJ's clutch, and it shows the same washer, called Thrust Plate #1, here's the part #: 360-16154-00-00 PLATE, THRUST 1 .

What you have is Thrust Plate/washer #2, inside the basket!

And, yes, without it you can't depress the center star plate very far in to allow it to disengage the clutch plates, it holds the basket 2mm further out away from the engine case, is what the basket is supposed to press against during the use of the clutch, instead of the aluminum case and side of the bearing!
T.C.

[macnut xj]

According to my XJ service manual, there should be a 2mm (.080") thrust washer (the thicker one) installed on the main shaft first, then the clutch basket (they call it the "clutch primary driven gear". There should be a tube "spacer" that goes inside the hub of the basket before it goes on the shaft, then the thinner washer. Then the inner clutch "hub" is populated with discs in the proper order (starting with a friction plate and ending with a friction plate), the hub/disc assembly is installed in the "driven gear" (basket), and the spring washer, then the lockwasher, and then the nut is installed. The nut should be torqued to 50 ft/lbs, and the lackwasher tab bent over. Then you install the clutch spring, pressure plate, and clutch bolts. The bolts are torqued to 7.2 ft/lbs.
HTH

[xj11DAN]

Thanks, i ordered the thrust washer #1 from bikebandit should have it monday. THe washer goes on first, then the basket with the other washer on the inside. When i took the assembly out there was not a washer behind the basket, i have not moved the bike since disassembly and all the parts i took out are accounted for, i had to replace the the #2 washer because I broke it when i torqued the main nut in place after i replaced the clutches. I hope this fixes it. I am wondering if the clutch problems started with the thrust washer # 1 breaking up I think i will have to tear apart my oil filter and see if it is not full of metal shavings...

[TopCatGr58]

Hey Dan,

The reason you broke thrust #2 may have been due to the absense of #1, so that the inner collar sleeve may have been pushed too far outward, due to the lack of the #1 plate not being there, the whole basket was probably pushed too far inwards instead of stopping against the inner plate that is stopped by a lip on the shaft IIRC!? Well, it should behave much better with all the parts this time!! Good Luck!
T.C.

[xj11DAN]

okay here we go again.
got all the new parts in, new fibers, new thrust plate 1 and 2, new cable. put all of it back together and the clutch engages but seems to slip as i rev the motor (okayu on flat ground but when i accelerated to go up a hill i could feel it slip for about 6 or 700 rpm then catch up. any suggestions, i think i will have to pull it all out again and try to scuff the steel liners up a little more than i did to give some bite to the fibers? any other ideas? I am about to drain the oil for the third time in less than 30 miles.

[chevy45412001]

proper adjust

Are you SURE you have the clutch adjusted properly at the right side by the engine? Remove the two screws that hold the cover on ,loosen the lock nut back out the set screw a little (to begin fresh ) then turn set screw in til you have lite contac. After lite contact , back set screw 1/4 turn out. Now while holding set screw (so it doesn't turn ) tighten lock nut again. Take slack out of cable by the handle bar. You should be good to go.

[xj11DAN]

I will try that first. On the way back home, when i pulled the clutch all the way in it seemed to get stuck in the in in position so maybe it has moved. I will try it in the morning and see what happens.

[TopCatGr58]

Hey Dan,

I hope you didn't move the clutch lever throwout rod and assembly too much when you put it back together. There is a warning in the manual about if that lever is turned too far, then the loose bearings can fall out, and it will be uneven, etc.

If you didn't readjust it after putting it all back together, then it's too far in, keeping the plates from mating completely, since with the extra 2mm thrust plate the basket is sticking further out towards the case, so adjusting it should fix the slipping!

T.C.

[chevy45412001]

curious

Hey there XJ Dan, did you get your clutch straightened out? just wondering?

[xj11DAN]

no luck yet, I have readjusted it and still getting a lot of slip in the thing. I think i will try to pull it all again and make sure that the liners are scuffed a bit to give them more bite. I cleaned them with chemtool and that is all i did to them the last time. if not any more luck i will take her in to the shop.

[wallyfishing1]

Hi Dan,

How much freeplay do you have in your clutch lever? I like to adjust mine to the width of a dime. You want to loosen the cable at the lever before you make any adjustments in the transmission. And no disrespect to macnut but i think the starplate bolts are torqued to 7.5 ft pds

[macnut xj]

None taken! But that spec was quoted directly from my factory XJ service manual.

[xj11DAN]

I have about 1/8th inch of lever play. I have tried taking more or less in with the cable but ot no avail. the bike goes through the gears ok and has no problem going in neutral but when you crank back on the throttle you can feel it slip. When i took out the old fiber plates the backs sides of all were worn off and down to almost metal it was difficult to get it to go into gear and that is no longer the problem.

[xj11DAN]

well here I am again, still no change in the slip. I have pulled the plates and scuffed them up a bit and readjusted the whole set up again, the *&@&#* thing still slips, Seems i read a few weeks back about adding an extra steel plate any idea where to get one? i have not been able to find one locally ( at least not a flat one) I bought a complete clutch assembly at the local bike salvage but the only flat plate has a couple of teeth missing. good thing i got hte whole assembly for 5 bucks or i would have been po'd