need some info on my clutch

everyday12s

everyday12s

XS650 Enthusiast
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hello everyone im new to this forum thing. so here goes. i have a 78 xs650 that i recently rebuilt the top end and put in my frame. my first gear is acting like it skips(like pulling in the clutch without letting off throttle then dumping it) it used to do it only once now its doing it so much i can barely use first gear??? took my clutch cover off to see if anything looked suspect. Nothin. reasembled now i have no clutch. nothin fell out on the clutch basket side the rod n ball are still n place. would my worm gear have turned or somethin?? sorry for the long pst but any help would be appreciated.
 
So you took the right-side cover off to inspect the clutch basket, and then after re-installing the cover, your clutch now doesn't work? Did you remove the left-side cover also? If so, did you visually confirm that the ball in the worm gear mechanism is still there?

Here's an exploded diagram of most of the XS650 clutch assembly. Does your bike's assembly match this?

clutch - missing washer.jpg


BTW, the 1st gear problem you're describing sounds a lot to me like your chain is loose or you have a worn sprocket so that it's jumping teeth.
 
Be aware that that drawing is the one with the notorious "missing washer". There should be another flat washer shown between the radial bearing (#3) and the inner basket (#2).
 
yes that looks like mine as far as i can tell. i didnt get the basket off i just wanted to inspect clutches n such. no i did not take off the left side cover( stator side) yet it got dark on me and i was aggervated..lol. as far as worn counter shaft its new as is my chain. one of the reasons i think its my trans?? but ive had had pan off and never seen any big metal pieces.. :wtf:
 
So you had the plates out? Did you properly align the pressure plate when re-installing it? There's an alignment mark, a dot on the inner hub that must show through a hole in the pressure plate. If it doesn't the clutch won't work right.

PressurePlateAlignment.jpg
 
- slipping clutch
adjustment..loosen cable off at lever, adjust at worm, adjust at lever, check worm for ball, lubrication and cracking​
weak or damaged pressure plate springs​
springs not properly screwed in​
pressure plate not aligned​
worn, warped or oil impregnated friction plates​
clutch cable doesnt have enough play​

- problems shifting
clutch drag​
weakened shift drum stopper spring​
worn dogs and receivers​
worn, bent shift forks​
bent shift shaft or damaged shift arm​
worn, broken gear teeth​
worn counter- or main- shaft splines​
 
well that fixed problem b. lol had no idea about that lil alighnment mark. thanx guys. now back to problem a. i have a spare 78, 447 engine how bad is it to split the cases and swap out the gear sets?? any usefull tips will be greatly appreciated.
 
Not difficult, just time consuming. And watch out for the one hidden bolt -- behind the right-side cover somewhere. Somebody here will tell you exactly where. :)

I'm about to split the cases on my '78 too. Got MikesXS's OD 5th I'm gonna install, so don't feel so all alone :cool:
 
yea i think that bolt is behind the clutch basket. i was lookin into that overdrive gear to but i think im just gonna swap out trannys. seems less painful. hey not sure if im doin somethin wrong but cant get my pic to come up beside my name?? lol
 
everyday12s said:
yea i think that bolt is behind the clutch basket. i was lookin into that overdrive gear to but i think im just gonna swap out trannys. seems less painful. hey not sure if im doin somethin wrong but cant get my pic to come up beside my name?? lol
Click to expand...

Well, I guess it all depends on the sort of riding you'll be doing. One thing I've never enjoyed about my XS was how tightly wound out it feels on the freeway. The OD 5th will reduce the freeway revs while not affecting the bike's acceleration through the lower gears the way changing sprocket ratios will.
 
- to undo start at #18 - each a half turn
- to do up start at #1 - each a half turn

005_063.jpg
 
inxs, where did you find those images? I'd like to find a set of them a bit larger so I can print them out and add them to my reference files.

Interesting shifter, eh?
 
I tried running the text through some of the free translators on-line but it doesn't come out quite right. The sentences are all jumbled up and not put forth in the English manner. I'm thinking this would be a worthwhile winter project, though. Maybe with inxs's help we could "crack the code". It is a most excellent manual, one of the best I've seen.
 
When I first saw it they were talking about an english version. Maybe inxs could/would check on if they are still working on it.
 

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