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A quick update, even though I didn't suspect the clutch cable, I was wrong, on a whim I ordered a new motion pro cable and compared it to the other before install. At first I thought I accidently ordered the wrong one, even though the cable itself was longer, the part exposed from the jacket...

Hi John, I agree this site is fantastic for help, clutch is still a bit sticky, I'm wanting to open her up again to check tolerances, I just realized one of my gear shift cam pins was lost too, I cant get past third, looking for just the dowel pin to replace is fun. I'd love to talk bikes and...

Hi does anybody know where to get a replacement pin? I can only seem to find Kawasaki part 92042-030 http://www.ronayers.com/ProductDetails/N/687/SKU/1085794 which is 4x13.8mm. As I am short 1 pin, would that work for an '81 special?

So just an update, checked the spark plugs, they were dirty, I had flooded it, had to change the oil, it smelled of gas, put in iridium plugs and it fired right up. I'm still having issues with the gears disengaging with the clutch lever, I had the right side off again the clutch only moved out...

Hi jamesgs4, should I be checking that at the battery terminals?

Had it trickle charged Fri night - Sat am. so it was fully charged up yesterday, (on a new battery when I bought the bike last month) Went to start it up today after riding it around yesterday, just 24hours ago, and I'm met with backfires aplenty today and poor idling and generally not keeping...

Leo thanks again for the detailed info, it helps tons. I ended up putting it up on blocks and readjusted the clutch adjuster and handle adjustment, seems the clutch just needed to be played around with some more until the back wheel stopped spinning while in the air, however took her for a spin...

Thanks Leo, I ended up getting a new assembly worm from xs650direct, as well as a tap and die, which fixed the thread issue. Put it in and adjusted according to several places on the web. Screwed cable at handle all the way in, then went to worm adjuster screw and turned till met the clutchrod...

My clutch adjuster is no longer adjustable. I took off the right side again to double check the clutch assembly have the register lining up with the right bolts. I guess the next step is to order a new adjuster and give it a go. Anybody have experience rethreading the crankcase holes? Tap and...

XSLeo that did the trick!!!! Got it running!! Now I seem to have an issue with the clutch worm seems like the nut is securely afixed to the bolt no amount of lube will get it to unjam just short of stripping the screw head. There was an extra little ball bearing sitting at the outer edge of the...

That's what the problem seems to be from my memory I'll take the top off to confirm the out of 90. The manual was weak with an as detailed explanation. Thanks! Can that be done from on the bike? I'd hate to tear it off the frame again.

So I bought myself a manual, tore down the engine down to splitting the crankcase and checked it all out, no damage apart from the flakes at the bottom of the engine, cleaned it out and put it back together, positioned camshaft back at markings for top dead center coinciding with the alternator...

So I got bad news from the bike shop, there were metal flakes in my oil and the transmission looks in bad shape, they recommended finding another engine to put in it. Clutch is fine though. I'm dissappointed that I only got to ride twice on it. I guess I'm looking for some advise, should I part...

Yeah its stock, wrong terminology, left foot shifter was stripped, threading on the rod connected through the clutch is fine thank heavens, I've ordered a bunch of parts through the XS650Direct (site for Canada) and was really inexpensive compared to the yamaha motorbike dealer $13.50 for a foot...

Thanks, I went out and bought Castrol 20/50 synthetic (car) oil will that do? Now to locate a 27 mm, probably will take half a day off of work to figure out if I can just swap oil and secure the pedal to see if that will do, and go from there, if I can't fix the pedal issue I'm going to have to...

Hi all first post took my '81 xs650 special out for its second run after buying it of craigslist yesterday, I had added about 1/3 cup of slick50 today, and went riding, long story short, clutch pedal went wonky slipping up and down when stepped on and feels like little to no tension on cable...