Clutch replacement

[cajun31]

This could be a cheaper solution. Motorcycle Motorbike Universal Throttle Clutch Emergency Brake Cable Repair Tool | eBay

[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.

By now you guys must believe you're dealing with an idiot. I've replaced clutches and cables. This is the first to give me fits. I reinstalled the old cable today. Now everything is adjustable. However, I can't adjust the creep out. I can't go from 1st to neutral. I'm probably going to reinstall the old frictions.

To recap, I had a bit of a slip in the clutch in high gear. 100,000 plus miles. I replaced:
Vesrah clutch springs
Vesrah friction plates
OEM clutch lever
Motion Pro clutch cable.

Currently, the clutch doesn't release all the way. The last adjustment, I turned the screw in, backed off less than 1/8 turn. Lever free play at 2 mm. I still have creep!

[Radioguylogs]

By now you guys must believe you're dealing with an idiot.

/\ Quite the opposite.

Most of my Motion Pro cables have been fine. I just had trouble with that one SF throttle cable.

Anyway, I feel your pain. Soon I will be reporting the results from the valve job on my SF.

[jetmechmarty]

OK. Bike in 4th gear and on the centerstand. I squeeze the clutch lever to the grip and try to turn the rear wheel. There is far too much resistance trying to rotate the wheel. Sometime this weekend I will take it all apart and find the issue. My hunch is that I screwed something up or the frictions are too thick. I will report back with findings. As usual, thanks for the support.

[DEEBS11]

Sometime these things happen with a routine job. I am working on 81 CB900 carb throttle shaft seals (felt type) and after many hours of work there is still some air leaks and the idle is erratic after what appears to be a clean sync. Idle changes when you spray carb cleaner at the throttle shafts. Guess what? They come out again, disassemble and have another go at it with another new set of seals. You learn and then you move on to the next job. This is the life of an antique bike mechanic. Wouldn't change it for the world.

[jetmechmarty]

This gear circled in red does not turn. I assume that’s the starter gear. I installed the clutch basket (no plates) and I can’t rotate it in neutral.

When I rotate it, I rotate the entire engine. How did this happen and what am I in for now?

[jetmechmarty]

Sorry, I have my thinking cap on backwards. Friction plates drive.

[jetmechmarty]

It's fixed. It's perfect. Here's where I went wrong:
I pulled the specs from my FSM on my laptop. I watched the Steptoes video about clutch replacement and carried the Clymer book into the garage. I will not callout Steptoes as wrong, but when I installed the assembled clutch basket, I could not tell if the basket was seated all the way and it wasn't. When I installed the basket by itself, I found it to be fiddly. It resisted my efforts to seat it fully, but I could see when it went on all the way. Another thing is that the Clymer book calls for a 2mm thick thrust washer behind the clutch basket. That's wrong. The 3mm thick washer goes behind the basket, the 2mm thrust washer goes on after the basket. I did the assembly in accordance with the factory service manual.

In the end, my six springs were worn out. My clutch lever was roached. My clutch cable was stretched and dragging even after lubricating it. I reinstalled my OE frictions as all are still 2.9+ mm thick.

With a properly assembled clutch, the Motion Pro clutch cable fits perfectly!

I just ran some miles on it, and I can't remember when it shifted so well. Pure joy! I did the 5th gear 40 to 80 mph roll-on test and there's no slipping. Lever, cable and springs were the necessary fix.

[bikerphil]

I could not tell if the basket was seated all the way and it wasn't.

Awesome, glad you got it solved. I'm surprised it even worked at all like that.

Interesting about the error in the Clymer manual.

[jetmechmarty]

I'm surprised it even worked at all like that.

Interesting about the error in the Clymer manual.

Not very well, I assure you.


#27 is 2mm thick. #30 is 3mm thick. That kind of confusion wasn't helping.

I think DiverRay said just replace the springs. That would have worked though the worn-out pivot hole in the lever would have continued to give me a poor release.