XJ600 Clutch nackered, Pull rod broken?

[adengtg]

Was testing my 97' Yamaha Xj600N the other day when i pulled the clutch and nothing happened. managed to get it into gear and check the cable which is fine. Looked at the release lever and it was completely loose. seemed to be no resistance on it at all and was not operating the clutch at all. Took the clutch cover off and had a look inside.

It seems that without taking the clutch its self off, that the "Pull rod" is completely loose and doesn't seem to be doing anything. I have no idea how to fix this or what it really means to be honest. just looked at the manual and saw the pull rod wasnt doing anything useful.

I will attach a video or two and some photos on a google drive to give a better explanation of the issue.

https://photos.app.goo.gl/r5zbeGjARr7vn7h57

Just in need of some advice as to what is broken and how best to fix it. Ive not had any experience working on clutches so i dont really know whats what, will try by best to fix it myself though.

Thanks very much for the help guys!

[rpsmith79]

This might help you understand what is supposed to be going on

https://www.youtube.com/watch?v=TcYsV063lk8

Looks like you push rod is actuated via the rack and pinion (the rack being the straight gear teeth section on your push rod, and the pinion being the gear wheel on the clutch cover, actuated by the clutch lever)

So make sure when you put it back together that the rack and pinion mesh correctly
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Current Bike: Honda CG125 ES4 // Honda CB600FS Hornet // Triumph Street Triple R

[adengtg]

[rpsmith79]

No idea i'm afraid

Have you looked up the parts drawing online at somewhere like Fowlers or CMS, they can usually help understand what is supposed to go where, and what might be missing/broken

Here you go, clutch assy from an XJ600, 1997 year

https://www.cmsnl.com/yamaha-xj600n-1997-4ke7-all-countries-274ke-300e1_model38905/partslist/0016.html#.W88q23tKjIU
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Current Bike: Honda CG125 ES4 // Honda CB600FS Hornet // Triumph Street Triple R

[adengtg]

[Riejufixing]

[adengtg]

[Riejufixing]

[adengtg]

[adengtg]

[A100man]

The 'wobbly' push plate rod is OK I think. You need to look inside the clutch cover and see what the mechanism there is like (damaged?). Check all parts against the diagram posted above. Maybe post a photo of teh clutch cover
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Now: A100, GT250A, XJ598, FZ750

Then: Fizz, RS200, KL250, XJ550, Laverda Alpina, XJ600, FZS600

[Riejufixing]

If you fit up the pull mechanism in the (dismounted) pressure plate to the actuator in the cover does it all seem OK, a good fit and not so slack that the teeth don't engage (and are all the teeth intact)? The thing is if the clutch just stopped working then something must have happened!


EDIT: It occurs to me that the clutch cable (which you say is OK) must fasten to the end of the actuating mechanism; is the connection and the attachment of a lever arm (?) secure, and any splines/square adjustable (?) join OK?

[bikenut]

Was testing my 97' Yamaha Xj600N the other day when i pulled the clutch and nothing happened. managed to get it into gear and check the cable which is fine. Looked at the release lever and it was completely loose. seemed to be no resistance on it at all and was not operating the clutch at all.

Ain't cmsnl exploded views great, a picture tells a 1000 words.

Is the actuating arm slipping on the clutch arm shaft, splines knackered perhaps or just the pinch bolt loose ?

clutch hub nutted on so no real special tools needed apart from a means of stopping the hub rotating, but you have a gearbox and rear brakes eh.

All that info from a diagram.

You do not have to remove the clutch hub or basket to remove the clutch plates but perhaps it would be easier to remove the last metal sprung loaded plate, the one that's circliped on.

The clutch was not slipping just not releasing ?
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nuts about bikes

[R1stu]

Ive got a complete engine spare, going be breaking down for parts if need anything for the clutch side.
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Current bike 1991 Honda ST1100 Pan European, 1986 Honda cb350sg (Finished)

[adengtg]

[bikenut]

I think some more pics are in order here.......you have the cmsnl exploded view so know what stuff looks like......

the clutch friction plates will have a service limit thickness, below the limit will influence clutch slip. The coil springs will have a service limit poundage, weak springs cannot clamp the worn friction discs etc tight, so the clutch slips. 2muew w r, but count the friction faces, as that formula assumes a 2 friction face clucth system.

So, the clutch end cable lever on the engine has good splines and so does the pull "shaft", so no slippage there ??

The rack system is all ok, see the picture of the "pull clutch release" part, the bit with the rack held in by what looks like a roll pin or spring dowel, that is ok ?

What the pull part pulls against is all ok, like the thrust bearing, the bit with the clock face rollers and what they roll on, are all ok ?

How is gear selection, bit of a daft question as the clutch is usually involved with that, and how is the gearbox input shaft end float, any more than a tiny bit of in and out movement means possiblel bearing problem....

clutcvh friction plates and metal plates thickness and all is ok with the innermost metal plate and its "spring" ?


What is the up to date fault, you pull the handle bar clutch lever to the handlebar and what happens exactly ?

I assume the handlebar end lever and pivot etc. is all ok as is the cable inner and outer, and any mid cable adjuster etc. ?

Pics and a video might be good.....
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nuts about bikes

[cb1rocket]

Look at the shaft in the clutch cover that conects to clutch cable, your most likely find that it has snapped.
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Honda H100S2 Rebuild - https://www.bikechatforums.com/viewtopic.php?t=253852

[cb1rocket]

Your looking for this shaft, its most likely has snapped above the pinion.

https://i.ebayimg.com/images/g/4oEAAOSwvvBaoYx5/s-l1600.jpg
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Honda H100S2 Rebuild - https://www.bikechatforums.com/viewtopic.php?t=253852

[cb1rocket]

Full clutch unit

https://www.ebay.co.uk/itm/1992-2004-YAMAHA-XJ-600-S-DIVERSION-4BR-CLUTCH-COVER-ARM-0044/271467456644?hash=item3f34b8a884%3Ag%3A3HkAAOxycD9TW7RX&LH_ItemCondition=4
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[A100man]

[adengtg]

[cb1rocket]

there are NO photos of the clutch cover. I'm talking about the clutch rod in the clutch cover. Forget all the pictures of the clutch assembly on the engine that you took. None of that seems broken.

You mentioned that the clutch actuation rod on the cover was all loose and floppy. It shouldn't be
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[adengtg]

[cb1rocket]

sorry. just seen that video, didn't know it was a video. The only thing i can think of is that the splines to top of actuation rod is stripped. can you get me a picture of clutch cover inside and rod rotation direction. i got the feeling the cover has worked loose and not pushing on the rod.
____________________
Honda H100S2 Rebuild - https://www.bikechatforums.com/viewtopic.php?t=253852

[adengtg]