Tightening the clutch nut binds the clutch shaft

[maverickbluer1]

I bought a 1974 XS660 447 off eBay for a custom project. Unfortunately, I didn't pay much attention to the clutch when I tore it apart for rebuilding. By the way, it's my first four-stroke engine rebuild, so I'm a complete newbie.

I've carefully followed the washer sequence as described in several threads. Before I tighten the clutch nut, everything is good and the shaft and all its components rotate freely. After tightening the nut to 43 ft/lb, the whole assembly binds up and becomes very hard to turn. I have to use a socket on the main drive to turn the crankshaft.

As I understand, the clutch should turn as freely after tightening the nut as before.

I've installed everything except the outer basket and it binds up as well when the nut is tightened.

Has anyone been encountered this before? Any suggestions greatly appreciated.

 

[jetmechmarty]

When you look through that little hole, do you see the dot? You must assemble it with the proper alignment. That would be the dot through the window.

 

[mike in idaho]

The washers behind the clutch hub and drum are out of sequence.

 

[maverickbluer1]

When you look through that little hole, do you see the dot? You must assemble it with the proper alignment. That would be the dot through the window.

Even before I attach the pressure plate the inner basket is bound up. Here's a pic. At this stage the outer basket turns freely but the inner basket is very hard to turn.

 

[maverickbluer1]

The washers behind the clutch hub and drum are out of sequence.

Here's my washer stacking sequence. Can you see a problem?

 

[maverickbluer1]

The pic is upside down so it goes right to left.

 

[Jan_P]

Taking this out of memory and have not looked it up .there are different versions of Clutches
But should there not be Locking washer with tabs that folds over the nut If so it restricts the horizontal movement of the nut

 

[maverickbluer1]

Taking this out of memory and have not looked it up .there are different versions of Clutches
But should there not be Locking washer with tabs that folds over the nut If so it restricts the horizontal movement of the nut

Mine seems to be a version that doesn't use the locking washer. It doesn't have the slots that the tabs fit into. Please advise if you think this is in error.

 

[Wingedwheel]

You have to make sure that the bearing and thrust washers are positioned correctly. If one or the other is out of line your clutch basket will bind.

 

[Jim]

 

[Jan_P]

Mine seems to be a version that doesn't use the locking washer. It doesn't have the slots that the tabs fit into. Please advise if you think this is in error.

Please compare Your 1974 with a parts list online
and
Jims Picture in # 10 above

The washer I was talking about is No 9 in Jims Picture above

If I recall right there are 3 different clutch versions

 

[maverickbluer1]

Please compare Your 1974 with a parts list online
and
Jims Picture in # 10 above

The washer I was talking about is No 9 in Jims Picture above

If I recall right there are 3 different clutch versions

Jan_P my clutch looks like this diagram from Clymers. It's actually a TX650. My inner basket doesn't have the slots for that washer (#9). I have one and looked at putting it in but there's just no way. Mine has a dished washed that I think serves the same purpose (#13 in the diagram).

 

[Jan_P]

Testing This Sir
In Your Photo there are 3 Items
Between the baskets If I get this right

But on the Exploded view only 2

Maybe the axial bearing is able to split

On Jims # 10 there are thicknesses on washers 2 and 5 perhaps shifted ?
5 and 7 ?

 

[maverickbluer1]

Testing This Sir
In Your Photo there are 3 Items
Between the baskets If I get this right

But on the Exploded view only 2

Maybe the axial bearing is able to split

On Jims # 10 there are thicknesses on washers 2 and 5 perhaps shifted ?
5 and 7 ?


View attachment 342645



View attachment 342646

Ahh thank you. I followed a couple of YouTube videos but they were all the arrangement that had the lock washer. I’ll take one out and see if that helps. I’ll need to figure out if thst washer between the baskets is thick or thin. I’ve bought some extra parts trying to get this to work. Here’s hoping that’s the problem

 

[gggGary]

 

[maverickbluer1]

Ahh thank you. I followed a couple of YouTube videos but they were all the arrangement that had the lock washer. I’ll take one out and see if that helps. I’ll need to figure out if thst washer between the baskets is thick or thin. I’ve bought some extra parts trying to get this to work. Here’s hoping that’s the problem

I removed the third washer but it didn't help. There's a lot of slack between the outer basket and the cases. See the video at https://cardomoto.com/img_2195.mp4. Does that hint lead to more thoughts about the problem?

https://cardomoto.com/img_2195.mp4.

 

[5twins]

That early drawing is in error and omits a needed washer, so don't take one out. Do check the washer thicknesses though. You need a 1mm and a 2mm thick washer behind the main basket or it will rub on the case. Also take care when installing the bearing between the inner and outer hubs. It can slip off to the side and that will bind things up, maybe destroy the bearing as well. Here's a good drawing showing the washer thicknesses and sequence .....

Make sure the small washer goes on first behind the main basket. It spaces the basket away from the case by only making contact with the inner race of the case mounted bearing.

 

[Wingedwheel]

Also take care when installing the bearing between the inner and outer hubs. It can slip off to the side and that will bind things up, maybe destroy the bearing as well

What he said…

 

[maverickbluer1]

That early drawing is in error and omits a needed washer, so don't take one out. Do check the washer thicknesses though. You need a 1mm and a 2mm thick washer behind the main basket or it will rub on the case. Also take care when installing the bearing between the inner and outer hubs. It can slip off to the side and that will bind things up, maybe destroy the bearing as well. Here's a good drawing showing the washer thicknesses and sequence .....

View attachment 342651

Make sure the small washer goes on first behind the main basket. It spaces the basket away from the case by only making contact with the inner race of the case mounted bearing.

Verified the stack sequence. See pic #1. On the back on the inner basket (I guess they call it the boss) there's a star shaped mark. See pic #2. I can't see anything that would make that mark. Am I missing something?

 

[5twins]

I think that star shape is just the outline of the steel splined insert that's fitted into the aluminum hub. Did you confirm washer thicknesses? The two large 2mm thick washers are the same and could be swapped (2nd and last washers in your pic). Maybe things would fit better that way.