clutch noise

DIRTY DOG

DIRTY DOG

XS650 Guru
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fuc****** sorry it pissing me off just got the bike done for the chop off
and now has a clutch noise, fixed the loose clutch basket, heres what i have
new clutch cable,new 1 pice clutch rod (bearings are there), new 8 plate clutch disk set up cleaned warm gear assymnew springs new bolt kit ( from mikes xs )
heres what it doing pull clutch in and it makes a grinding noise if i let it out a little it gos away, clutch holds ok I guess not have enough miles on it yet help I have looked and can't find any fix's on here help please and thanks
 
DDog, if your clutch plates stackup thickness is too much, the pressure plate will be too far out, and could contact the side cover. A range of 29.0mm to 29.4mm is right.

Edit: Also if the clutch hub isn't fully seated...
 
Did you put the bearing for the 2 piece pushrod back in there? cause that bad boy is not suppose to be in there and that's why mine was grinding against the side cover.
 
has 1 bearing in the worm gear 1 pice push rod bearing the the push rod crown,
the 1 pice rod has been in there fromt the start of this eng, only started making noise after the new clutch ond mikesxs bolts
 
TwoManyXS1Bs said:
DDog, if your clutch plates stackup thickness is too much, the pressure plate will be too far out, and could contact the side cover. A range of 29.0mm to 29.4mm is right.

Edit: Also if the clutch hub isn't fully seated...
Click to expand...

if the hub isn't seated would the clutch still work ok?
 
Kinda. During assembly, it's possible for that last thin washer to slip down and get caught behind the hub, keeping it from fully seating. The basket would show a little extra end-play, about 1mm (0.040"), that may not be noticed.

Edit: Correction, brain fart, just want to ensure that the washers are stacked correctly, and haven't slipped down off the sleeve. This post explains it better:

http://www.xs650.com/forum/showpost.php?p=267024&postcount=49

Also, you may want to review Ippytattoo's 8-plate mod, concerning the required machining for late model hubs, if that's what you have...

http://www.xs650.com/forum/showthread.php?p=342697#post342697
 
Last edited:
Here's another take on this thing. When the clutch plates are assembled, there should be some protrusion of the hub splines for the pressure plate to engage. As the pressure plate moves in/out 1.5-2.0mm (0.060"-0.080"), those splines need to remain engaged.

Notice how deep the splines are on this pressure plate.
View attachment 6706

Notice how much exposed hub spline exists with the clutch plates installed.
17012009444zr3.jpg


In these two pics, notice how the pressure plate fits recessed into the basket fingers.
View attachment 46564

View attachment 46997

Links for reference:

http://www.xs650.com/forum/showthread.php?p=342697#post342697
http://www.xs650.com/forum/showpost.php?p=384299&postcount=7
 
Now, somewhere in here, one of our members posted a really good youtube video of his pressure plate action, moving in/out about 1.5mm. I believe sometime within the last 4 months, but dang it, I can't find that thread/post with his video. Anybody remember that?
 
I'll just have to pull it down and see what I can find, I know the hole and dot are lines up, fixed one problem ( Thanks you the inout play is fixed ) now theres a noise haha
 
DAN
Sounds like a clearance problem. What you can try just to see is pull one plate and one metal and see if noise goes away. I did have a problem like this on a café bike and when I pulled clutch in with bike running I could hear noise and motor bogged a little. Plates were too thick and pressure plate hit cover. But there was a mark on cover. Changed fibers and noise went away. Go back in and double check everything.
 
TwoManyXS1Bs said:
Now, somewhere in here, one of our members posted a really good youtube video of his pressure plate action, moving in/out about 1.5mm. I believe sometime within the last 4 months, but dang it, I can't find that thread/post with his video. Anybody remember that?
Click to expand...

Believe that was me perhaps... ;) ill at least see if I can find the thread.:bike:

Perhaps this ? http://www.xs650.com/forum/showthread.php?t=40469
 
The clutch side cover is thick, cut in some clearance???? Or if it's the bolt heads, machine them down a bit, Mohamed / mountain.
 
TwoManyXS1Bs said:
Here's another take on this thing. When the clutch plates are assembled, there should be some protrusion of the hub splines for the pressure plate to engage. As the pressure plate moves in/out 1.5-2.0mm (0.060"-0.080"), those splines need to remain engaged.

Notice how deep the splines are on this pressure plate.
View attachment 6706

Notice how much exposed hub spline exists with the clutch plates installed.
17012009444zr3.jpg


In these two pics, notice how the pressure plate fits recessed into the basket fingers.
View attachment 46564

View attachment 46997

Links for reference:

http://www.xs650.com/forum/showthread.php?p=342697#post342697
http://www.xs650.com/forum/showpost.php?p=384299&postcount=7
Click to expand...

it looks like that,all seated holes is lined up, found the the hub is rubbing on the cover can i use the earlier style hub ( pressure plate ) the one with out the splins in it and still have a strong clutch?
 
I'm not aware of any thickness differences between those two pressure plates.
There IS a difference in the 79-83 (?) Hub, different rear face distance.

So, sounds like your pressure plate may be protruding too far.

The 8-plate clutch mod in Tech, plus Ippy's threads, address the machining work to the contact faces of the hub and pressure plate, to get the required clearance. Wouldn't take much, maybe remove 0.5mm (0.020") total, from one surface, or divided between the two surfaces.

On the early pressure plate, torque would be absorbed by the clutch springs' posts on the hub. Later is handled by the splines. A better system, in theory, but haven't heard of any issues with the early system.

Edit: Another thing to check is the alignment of the primary gears. They should exactly line up, parallel. If the clutch basket sets out too far, you'll see it at the gear contact area, and that'll push the hub out too far...
 
Last edited:
the splineless pressure plate won't work unless used with the earlier hub tryed it oh well now I know found two thin washers stuck together behind the assy removed it reinstalled every thing good to go, now I can see if it'll hold the 680 rephase.
THANKS FOR ALL THE HELP.
 
DIRTY DOG said:
the splineless pressure plate won't work unless used with the earlier hub tryed it oh well now I know
Click to expand...

Well, THAT's interesting.

DIRTY DOG said:
... found two thin washers stuck together behind the assy removed it reinstalled every thing good to go, now I can see if it'll hold the 680 rephase.
THANKS FOR ALL THE HELP.
Click to expand...

Great! (*whew*)...
 

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