XS650 shifting issues

[ryanglade]

I had my side cover off and the bike tore pretty well down. I finished putting it back together tonight and took it for a test ride. I was only able to shift into 3rd gear and it rode like the clutch was not disengaging all the way. Before tear down it worked good.

I proceeded to adjust the clutch following the manual and now I can not shift at all!!!

What am I missing?

Thanks!

[xsleo]

You may have assembled the clutch wrong. Mis matching the pressure plate to clutch hub. Hole in pressure plate lines up over dot on hub.
You might put the bearings and washers in the worng order or let one slip causing the clutch to bind.
Leo

[ryanglade]

I never tore apart the clutch, only took off the left side cover. The only thing I even took off the cover or anything that it exposed was the cable.

Someone on another forum suggested the cable was wore out. I replaced it with another xs650 clutch cable I had around and it works.

Thanks for your response.

[preston]

I think there is a little ball bearing in there also (at shaft /rod that can fall out unseen) , like the size of a small BB.
Pretson

[ShakerNorm]

Ryan - Check out this pic -
In bikes with a 2-piece pushrod, there's actually 3 BB's in there. 2 of them you can see in this pic (part #18), the 3rd one is staked inside of part #22, and should never come out - although occasionally it will if it's worn. If any of these are missing - you'll never get your clutch to work properly. If any are missing, they are all identical (Mike's p/n 39-6509) if you have to replace one.

Also - if you do pull apart your clutch - check out this thread xs650temp.proboards.com/index.cgi?board=sprocket&action=display&thread=12288 - it explains that same pic in detail - and tells about a washer that is "missing" from most manuals, but MUST be installed for your clutch to work properly, too. If you didn't pull apart your clutch, I wouldn't worry about it, though.

Mike's includes the "missing" washer if you order a new Torrington bearing (#3 in the picture, and Mike's P/N 39-6505). If you take the clutch apart, it's a good idea to replace them, as the OEM bearing is a POS (only 6 rollers), and Mike's is a much better part.