Clutch questions

[Wtc5617]

1972 xs 650…. I torqued the clutch basket to 58 ft lbs and it’s tight but there is no threads after the nut which seems concerning?

On top of that I cleaned off the old clutch plates/friction discs to re install and one broke, I figure I best replace them all, is there a kit that is superior?

I realize there has been changes to the clutch throughout the years and I’m sure mine is one of the first versions so I am unsure which one I should get

I used the correct washer set up before the basket, disassembly pictures and the manual

 

[Jan_P]

Need to be careful there -- taking this out of memory which is not perfect
But if I recall correct there exists 3 different clutch versions
Some have different thickness on Pressure plates and on friction Discs as well
that needs to sit at the correct place in the stack
And the sequence of the washers is important washer that also have different thickness
Perhaps can find a service manual on Line.
And there are Threads here on the Forum.

Again out of memory but should it not have a lock washer under the nut Mine is 1980 so it can differ

I would also replace friction disc plates once opened .

 

[Its been a long time]

My 77 doesn't have a lock (tab) washer under the centre nut. It has a concave dished washer instead. I expect earlier bikes may be different, but I don't have that information.

 

[jetmechmarty]

My 77 doesn't have a lock (tab) washer under the centre nut. It has a concave dished washer instead. I expect earlier bikes may be different, but I don't have that information.

I believe it should have both. The spring washer, then the special lock washer and then the nut.

 

[jetmechmarty]

1972 xs 650…. I torqued the clutch basket to 58 ft lbs and it’s tight but there is no threads after the nut which seems concerning?

I just went through this with my XS1100. I had that clutch apart three times. In the end my stack was correct but the basket was not all the way seated. Yes, what you have there is concerning. I would expect three exposed threads.

 

[Its been a long time]

I believe it should have both. The spring washer, then the special lock washer and then the nut.

Not according to the Yamaha service manual. Nut, spring washer and plain washer. Which is what's on mine.

 

[jetmechmarty]

Not according to the Yamaha service manual. Nut, spring washer and plain washer. Which is what's on mine.

View attachment 370414

Well then, the Factory Service Manual certainly trumps me. Admittedly, my very recent clutch work was on an XS1100. My XS650 clutch experience goes all the way back to the 1981 model. I still stand by my belief that the OP should probably have more exposed threads after assembly.

 

[Its been a long time]

Well then, the Factory Service Manual certainly trumps me. Admittedly, my very recent clutch work was on an XS1100. My XS650 clutch experience goes all the way back to the 1981 model. I still stand by my belief that the OP should probably have more exposed threads after assembly.

I'd expect to see say 1.5 threads exposed or thereabouts, typically.

I think OP needs to find a correct year shop manual and go from there I think. That way he's got the final word on how it should be.

 

[jetmechmarty]

I cleaned off the old clutch plates/friction discs to re install and one broke, I figure I best replace them all, is there a kit that is superior?

Yes. Replace all of the friction plates. I just bought a Vesrah stack. It was in spec. It works as OE. Later XS650s have 3mm thick plates. As I recall, 1970 though 1973 friction plates are thicker. I learned this when I attempted installing an early stack of Barnett plates in my XS650SK. Thy didn’t fit. So, please verify my words before purchasing friction plates.

 

[Its been a long time]

Some information regarding early and later clutch plates. This is from Heiden Tuning. They're not 100 per cent infallible but I would tend to believe them on this.

Clutch Friction Plates - Fit: 650's 1970-84 -check how much platesthere are in your bike!1970-73 model clutch friction plates are No longer available but these later types can replace the originals! (6 friction and 5 steel drive plates were originally used). To use these late type friction plates remove the old clutch plate separator O-Rings (discard), and add 1 additional steel drive plate and replace all 6 old type thick friction plates with 7pc. of this new type friction plate.
these plates are 3 mm thick!

From -

https://www.heidentuning.com/xs650-...ion-plate-set-6-pieces-3-mm-thick-detail.html

 

[jetmechmarty]

Some information regarding early and later clutch plates. This is from Heiden Tuning. They're not 100 per cent infallible but I would tend to believe them on this.

Clutch Friction Plates - Fit: 650's 1970-84 -check how much platesthere are in your bike!1970-73 model clutch friction plates are No longer available but these later types can replace the originals! (6 friction and 5 steel drive plates were originally used). To use these late type friction plates remove the old clutch plate separator O-Rings (discard), and add 1 additional steel drive plate and replace all 6 old type thick friction plates with 7pc. of this new type friction plate.
these plates are 3 mm thick!

From -

https://www.heidentuning.com/xs650-...ion-plate-set-6-pieces-3-mm-thick-detail.html

I did a similar alteration to my XS650SK. I installed the Alto plates from @gggGary taking my 6 plate clutch to 7 much like the Heiden description.

 

[zrx1100]

here is how it looks on mine

 

[zrx1100]

order of assembly

 

[Its been a long time]

here is how it looks on mine
View attachment 370432

I don't think I kept pictures of when I did my 650D, but that is exactly how I remember it. About one thread visible beyond the nut. No tab washer.

 

[Wingedwheel]

The early clutches were a little different. I upgraded one of my ‘72’s to a later basket, plates and disk’s. Assembly order stays the same.

 

[Wtc5617]

Some information regarding early and later clutch plates. This is from Heiden Tuning. They're not 100 per cent infallible but I would tend to believe them on this.

Clutch Friction Plates - Fit: 650's 1970-84 -check how much platesthere are in your bike!1970-73 model clutch friction plates are No longer available but these later types can replace the originals! (6 friction and 5 steel drive plates were originally used). To use these late type friction plates remove the old clutch plate separator O-Rings (discard), and add 1 additional steel drive plate and replace all 6 old type thick friction plates with 7pc. of this new type friction plate.
these plates are 3 mm thick!

From -

https://www.heidentuning.com/xs650-...ion-plate-set-6-pieces-3-mm-thick-detail.html

I’ll take a look, thank you. Hope this works for me i would prefer to not buy a whole new clutch assembly….

 

[Wtc5617]

The early clutches were a little different. I upgraded one of my ‘72’s to a later basket, plates and disk’s. Assembly order stays the same.View attachment 370440

Do you think a new clutch assembly is the better way to go? Seems like all the intricate parts of this engine have all been discontinued -_-

 

[Wingedwheel]

I know you’re in Canada but member @gggGary offers top quality fiber plates. If there’s something else you’re looking for check EBay for OEM parts or post here in the classifieds. I don’t regret upgrading.