Clutch replacement

[jetmechmarty]

Yep, my PartsNmore frictions measure about 2.6 so I can see with 3mm there wouldn't be very much room for adjustment.

That’s interesting. The stock plates are 3 mm. Clymer says to replace all of the friction plates if any one of them measures less than 2.8 mm. I might be misremembering but I think the factory manual says 2.9 mm. All of my factory plates are over 2.9 mm.

So, I might have to decide to put the old plates back or replace the cable again. I’m buried right now, but I’ll try one more shot at adjusting it.

[bikerphil]

The factory manual also says replace at 2.8

[jetmechmarty]

OK. With 2 mm free play at the clutch lever, the clutch will not release all the way. Shifting is difficult. The screw on the clutch must be turned in farther. That makes the lever too tight. It's time for me to give up on this cable.

[bikerphil]

Well, if your old cable turns out to be the same length, you may have to cut 1/4 " of the sheathing off to get it to work.

[DEEBS11]

the pivot hole in the lever is oval[/U]. I need to address that as well. I'm not sure when I can next get on this, but I'll let y'all know when I do.

I appreciate all of the input gentlemen.

The oval lever bearing might lessen the throw of the lever and it might have an effect on the plate separation.

[DEEBS11]

Parts unlimited cable:

https://www.ebay.com/itm/16789329778...Bk9SR9i14PG1Zw

[DEEBS11]

Rocky clutch cable:

https://www.ebay.com/itm/17722297003...Bk9SR9614PG1Zw

[DEEBS11]

NOS Yamaha cable:

https://www.ebay.com/itm/26680093667...Bk9SR4TnkPK1Zw

[DEEBS11]

Lever

https://www.ebay.com/itm/23675584917...temCondition=3

[DEEBS11]

NOS lever:

https://www.ebay.com/itm/20578064687...Bk9SR5C_tPO1Zw

[jetmechmarty]

The oval lever bearing might lessen the throw of the lever and it might have an effect on the plate separation.

Yes sir! I mounted a brand new NOS lever. I even installed the o’ring on the bottom. I’m wasting my time futzing with a cable that is too short.

[cajun31]

Yes sir! I mounted a brand new NOS lever. I even installed the o’ring on the bottom. I’m wasting my time futzing with a cable that is too short.

Interesting. The last couple of cables I bought were almost too long and yours is too short. I do believe both of mine were motion pros as well.

[jetmechmarty]

Interesting. The last couple of cables I bought were almost too long and yours is too short. I do believe both of mine were motion pros as well.

This is the first time I’ve had issue. I have Motion Pro cables on at least a couple of XS650s. They’re about perfect.

[Radioguylogs]

I had a Motion Pro throttle cable on my SF that was too long (or the sheathing too short). There was too much free play, even at the extreme of the adjustment.

I finally replaced it with an NOS OEM cable.

[DEEBS11]

I had two Motion Pro clutch cables snap on my Kawasaki 1000 & 750. The 750 sidecar rig had to be flat bedded home. Never again. They were quality cables about 25 years ago but not now. I now stockpile OEM cables only. All my XS11 cables are OEM. The tach, speedo & throttle cables (for the Kawasaki's) are not as stressed as a clutch cable so I have gotten away with Parts Unlimited with good results.