problems after new cable install

[kobra357]

I have a new to me 1981 XS650. It ran pretty ok and I road it most of the summer. I have read lots of information on here and even watched a good amount of videos too. It came with problems like the leaking of gaskets bad tires, basically maintenance issues all around. The clutch lever was brutal to pull. neutral was very difficult but not impossible to find. I read all the basics of how normal this was etc. The original controls grips cables etc. were really bad. I did notice when riding when in first at a stop with the clutch lever pulled you could feel it wanting to engage like the clutch was not pulled all the way even though it was. I basically replaced all the controls and cables. I replaced the clutch push rod gasket and went from a 2 piece to a one piece with NOS. after making sure my cables did not bind, following the routes and instructions from this site I was able to get it running again. Here is were I'm at a stand still. I can get the bike to idle but every time I try to engage first gear it stalls. I have adjusted and adjusted and adjusted my clutch perch and push rod until I finally purchased and new clutch worm assembly. I'm still getting nothing. I have also tried adjusting throttle/idle and even at higher rpms it stalls.

I have read that if you rebuilt your clutch some have had this problem and there are remedies to fix it that require making sure clutch was installed and replaced properly, but I NEVER touched or rebuilt the clutch or disks etc. Never even opened the right side case.

I hate asking but I'm at a crossroads and its been a month of me reading and investigating with no real solutions. I hope someone has some suggestions or can send me in the right direction. Winter is almost here and I wanted it to be in riding condition before snow falls.

thanks in advance.

 

[Its been a long time]

Just a simple suggestion, what is the engine idle speed set to? If it's set a bit low, it'll do what you say. Hope that helps.

 

[kobra357]

I am going to up it some more. I also found some articles on stuck clutch plates. I might have this issue too. Im going to check tomorrow. I think I remember not being able to find any other gears but 1 N and maybe 2? Ive been so focused and frustrated Im not sure.
Thanks for input.

 

[Raymond]

I'm sure you've read all about setting the clutch? But they can be quite finicky. On my XS, it was nigh impossible to get acceptable clutch action but when I took the clutch apart to investigate, the clutch pressure plate was not correctly aligned with the drum - the dot that needs to be lined up wasn't.

Wind adjuster at handlebar all the way in, move adjuster at l/h engine case till it just touches the worm, back off a tiny bit, say 1/8 turn, check you have a small amount of free play at the lever, tighten the lock nuts.

If the problem persists, you might have slightly distorted clutch plates?

 

[kobra357]

I figure I will rebuild the clutch and rebuild engine because of the leaks. Its frustrating because I never touched the plates. I only replaced a very old cable. It’s probably one of those if you replace one thing it dominos into replace everything. Like rabbit whole stuff. Anyway thanks for your advice

 

[Bruno_c]

When some bikes are left unused for some days their clutch may get stuck.
To free it, one solution is to pull the clutch lever and press the kickstarter.

 

[bosco659]

I figure I will rebuild the clutch and rebuild engine because of the leaks. Its frustrating because I never touched the plates. I only replaced a very old cable. It’s probably one of those if you replace one thing it dominos into replace everything. Like rabbit whole stuff. Anyway thanks for your advice

What grade of oil are you using and what’s the temperature there? Thick oil and cold temps will make for a dragging clutch until the oil warms up.

 

[gggGary]

Ignition off, in gear, front brake on, clutch lever in, use the kick starter. What happens?
you should feel a little drag but it should not turn the motor through.
An old guy take.
Bike acting like yours; First, engine off, I'll put it in gear, pull in the clutch and rock the bike fore and back, pulling, pushing on the handle bars, I'll keep at til the clutch breaks free. I've brought back cough one or two (50-60) of these from long term neglect and worse, I have yet to find a clutch that wouldn't break loose. It's not always easy but they free up.
Once it's loose; I'm gonna start it, hold the front brake, pull in the clutch, rev the motor, and stomp it into gear. There might be some drag but the plates should slip then go out and RIDE it, back roads, streets, lots of start and stop.
PS did you thoroughly lube that new Motion pro cable? They are dry when shipped.

 

[5twins]

Yes, I was going to mention the cable oiling. I didn't oil the first new clutch cable I installed on one of these and it pulled harder than the old one it was replacing, lol.