Clutch Issue

[IanDMacDonald]

Cleaned my steels, new fibers. After reinstallation, I have an issue with the clutch. It pops, and is very stiff when bringing the handle in (non-running), won't even go all the way to the handlebar without fear of snapping the cable. Obviously, I'm knowledgeable enough to know it's not engaging correctly. I'll probs have to pull the cover back off and see if the detent bearings are seated correctly, despite them being seated when the cover was installed. Another thought I have is the fibers may be dragging on the basket windows. Nothing else I can really think of. THoughts?

[cajun31]

Cleaned my steels, new fibers. After reinstallation, I have an issue with the clutch. It pops, and is very stiff when bringing the handle in (non-running), won't even go all the way to the handlebar without fear of snapping the cable. Obviously, I'm knowledgeable enough to know it's not engaging correctly. I'll probs have to pull the cover back off and see if the detent bearings are seated correctly, despite them being seated when the cover was installed. Another thought I have is the fibers may be dragging on the basket windows. Nothing else I can really think of. THoughts?

good thoughts already. stupid question time: could the cable be binding and is it and the plates lubed good?

[IanDMacDonald]

good thoughts already. stupid question time: could the cable be binding and is it and the plates lubed good?

Cable is not binding. Same routing prior to the clutch basket being removed. And, the fibers were soaked in oil overnight, prior to installation.

I will take it all back apart today to see if something is rubbing/sticking, or is the detent bearings plate came out of place.

[DiverRay]

Did you put in new springs? If so, WHAT BRAND! Barnett springs are best, OEM are second best, and most of the other springs sometimes work.
Pull the first cover, release the cable from the clutch mechanism and try the cable with it just hanging by the cover. That will tell you if it is a cable/routing issue.
Next, re-adjust the cable mechanism. The 12mm nut/phillips screw preload for the clutch. If freeplay is wrong, you could have too little, and are against the stops.

[Socer4m]

second on the clutch before anything, follow Ray's procedure or any xs1100 repair manual,,,,also could be the plates could be mixed up, metal, fiber, etc, maybe recheck the order of the plates,,,also could be clutch springs, but would think that if they are worn out, it would be easy to pull in. The Barnetts are best as the factory springs wear out pretty quick , especially as these bikes are older, definitely put new ones in with any clutch plate redo.....Mike in Sun Diego

[IanDMacDonald]

Hi guys- sorry for not following up. The cable was not binding up, and the TOB adjustment was not touched (all the way in, quarter turn out). Also, they're the Barnett HD springs from two years ago.

My guess is the clutch pack is binding up (too much oil?). I'll pull it back apart soon.

[Radioguylogs]

I don't know what a "TOB adjustment" is, but I guess it would be the free play at the discs.

You probably already know it, but just in case...

You don't turn the screw all the way in then out 1/4 turn.....you turn it in until it takes up the slack (not all the way in), then back it out 1/4 turn.

[jetmechmarty]

Does the XS1100 cover have the dot that has to be visible through the hole? If so, and it isn’t, that’s likely the issue.

Also, the XS650 uses the same plates. The early XS650 uses thicker plates. Is it possible the vendor sent you plates that are too thick?

[IanDMacDonald]

I don't know what a "TOB adjustment" is, but I guess it would be the free play at the discs.

You probably already know it, but just in case...

You don't turn the screw all the way in then out 1/4 turn.....you turn it in until it takes up the slack (not all the way in), then back it out 1/4 turn.

Actually, I didn't know this. Thanks Mike

[IanDMacDonald]

Does the XS1100 cover have the dot that has to be visible through the hole? If so, and it isn’t, that’s likely the issue.

Also, the XS650 uses the same plates. The early XS650 uses thicker plates. Is it possible the vendor sent you plates that are too thick?

Both 3mm in thickness. I matched them up before I installed them.

[cajun31]

Actually, I didn't know this. Thanks Mike

If you had that screw that misadjusted the manual states that the ball bearings can become disengaged from the retainer plate. Something to watch out for if you still are having problems after readjusting correctly.

[Radioguylogs]

If the screw was too tight, the bearings should stay in pace, and the symptoms would be exactly as described in the original post.

If the screw was adjusted too loose, then the bearings could fall out.

I think we can be optimistic a simple adjustment might solve the problem.

[IanDMacDonald]

UPDATE: It was a combination of two things:
1. I saw a video where the frictions were soaked in oil. I did this. I don't recommend not cleaning the excess oil off, as they were stuck to the steels. Kinda like the bucket shims.

2. There was an extra steel in there. 8 instead of 7. No idea.

Put it back together, and it pulls smooth.

[cajun31]

UPDATE: It was a combination of two things:
1. I saw a video where the frictions were soaked in oil. I did this. I don't recommend not cleaning the excess oil off, as they were stuck to the steels. Kinda like the bucket shims.

2. There was an extra steel in there. 8 instead of 7. No idea.

Put it back together, and it pulls smooth.

did you install a complete kit in the clutch springs and plates etc.? Just wondering why the extra steel.

[IanDMacDonald]

It was either already there, or carried-over from my parts bike clutch basket.