New Clutch Rebuild Problem 72 XS2

[ash13brook]

I have a guy working on my XS2.
I bought replacement friction plates, including the extra one needed for an XS2.
MikesXS didnt have steel plates in stock at the time, so I bought a couple off the "bay".
The clutch is together and seems to be functioning properly, but I cant pull the handle in without jerking it in. It's way to tight.
The guy working on it at first thought it was because of new springs, but I told him that it's way too tight.
I was wondering if the steel plates are thinner on a replacement clutch. I used an extra of the older type.
Also, I read something about alignment during reassembly. Is this more likely the problem?
And last. Does a 72 use a tabbed washer under the clutch hub nut?

 

[Mailman]

This is a thread started by 2M , he has done many many experiments to try and achieve a more efficient and easier to operate clutch. It is a great read.

http://www.xs650.com/threads/xs650-clutch-cable-experiments-and-tidbits.32945/

I too , found the pull at the lever to be excessive. So I worked at trying to get a better / easier pull.
Taking information from that thread and applying it to my XS2 , from that same link.
http://www.xs650.com/threads/xs650-clutch-worm-actuator-experiment-tidbits.31554/page-12#post-585696

Posts
#226 and 233

 

[Mailman]

More here, starting at post # 2652

http://www.xs650.com/threads/mailman’s-xs2-a-full-on-restoration.51520/page-133#post-590507

 

[TwoManyXS1Bs]

...The clutch is together and seems to be functioning properly, but I cant pull the handle in without jerking it in.

Without good lubrication, the clutch cable can hang-up inside the curved elbow, at the lower left sidecover.

...I was wondering if the steel plates are thinner on a replacement clutch. I used an extra of the older type.

You have to have the correct combo of friction/steel plates.
Read thru this recent, similar thread. Follow the imbedded links.

http://www.xs650.com/threads/1970-xs1-clutch.54746/

...Also, I read something about alignment during reassembly. Is this more likely the problem?

70-73 clutches don't use the alignment dot.

...And last. Does a 72 use a tabbed washer under the clutch hub nut?

70-73 clutches used a belleville washer with lockwasher...

 

[ash13brook]

Thanks, all.
I can see already that I gave the guy working on it the wrong steel plates.
I have the MikesXS clutch cable, so I think I'll go with the Motion Pro. That may or may not make a difference, but it won't hurt.
Then, I might have to go back to working on it myself so I have a better idea of exactly what's going on in there.
I had this young guy straighten out the electronic ignition and carbs because I was frustrated after a few years tinkering with it. He got it running great so I got lazy and had him do the clutch. But, now, I'm trying to figure out a problem I didnt cause.

Thanks for the start,
Matt

 

[ash13brook]

Oh, also, does the Motion Pro cable get lubed?

Matt

 

[Mailman]

Oh, also, does the Motion Pro cable get lubed?

Matt

The motion pro will make a BIG difference. It’s heavier and has strategically placed inner nylon sleeves. It should be lubed. The best method is to hang it up and fab up a funnel at the top then drip motor oil until it comes out the bottom. I also , afterward, apply grease to the cable where it slides in and out of the sheath at both ends.
You should also consider drilling your clutch actuating arm , to move the cable attachment point out to the end of the arm. It will increase the leverage and ease the pull.

 

[ash13brook]

Drilling the arm is also on the agenda.
I'm starting to get a little excited to finally be able to ride mine. I've been fooling around for 6 years trying to get it running good enough that I feel confident leaving the house without having my "recovery" trailer hooked up and my wife near the phone.
Thanks,
Matt