HELP! Clutch Issue

[davies2619]

My 93 (K) XJ600 Diversion has developed a clutch(?) problem that has me stumped.

It starts as normal but if I put it into first it cuts the engine out, it's then hard to put it back into neutral. Curiously this doesn't happen if the bike is on the centrestand. Any Ideas?

Please help the summer's starting next week.

[bear]

Please don't take this as patronising, but best to rule out the simple things first. Like most bikes, the 600 has a sensor which stops a running engine being put into gear when the side stand's down. If it's tried, the engine cuts out. I wouldn't mention it apart from the fact you mentioned the centrestand.

If not, then I'm sure you'll find an answer here. And welcome!

[m40man]

Yep - sounds like the sidestand switch to me, too!

[johnthebowman]

Welcome to the club Davis2619

I'm with Bear and Martin on this one. So the bike will only run when in first gear when its on the center stand.

If you fold the side stand down whilst its running in first gear on the center stand does it cut out?

If you sit on the bike with both stands up. Start it and put it in first gear with the clutch in does it cut out?

Please do not take my questions as patronizing either

[Padster]

It is quite common for the clutch to stick a bit on the 600. If it has rested a while you will get a clunk engaging first gear. With the bike on the centrestand it allows the wheel to turn round so the effect is less. You could try a cable tie on the clutch lever back when not in use as this will ensure ease of use. My XJ600 pre divvy was an absolute pain in the rear end for this until I started using this trick. My 600 Divvy wasn't as bad but still cut out if I left it a while.

[bobh]

Or free the clutch before starting the engine by putting it into gear and rolling the bike a short distance with the clutch in.

[davies2619]

Don't you hate it when you overlook something simple :-)

RE: johnthebowman "If you sit on the bike with both stands up. Start it and put it in first gear with the clutch in does it cut out? "

Yes it does,

the consensus is the switch so I'll test it tomorrow after work.
Thanks for your help guys.

Mark

[biblebasher]

i do like a happy ending!

[tone]

Im with Padster on this.

If its cutting out when you drop it into gear when you are on it with both strands up then it may not just be a switch issue.

Mine developed the same issue and I ended up stripping the clutch down, separating the plates then re-assembling and tweaking the clutch lever tension setting. The issue with mine was that the clutch cable had badly worn / stretched causing the bike to want to 'move' the moment the gear was selected whatever the position of the clutch lever. There was no noticable lurch forward, just a cut out on gear selection.

The switch anyway should be an easy first check then if not, id try the above.

Cheers
Tone

[johnthebowman]

My current theorem on this, is

If the cutting out causes a leap forward and clunk like you have stalled go with Padster and Tone

If it just cuts out like an electrical cut go with the other posts on this thread

[CD]

The clutch release mechanism in the engine can give problems. The vertical shaft which is turned by the cable runs in needle rollers. These collapse so the shaft floats around. This messes up the oil seal and lets water into the engine.

The clutch release bearing also tends to run dry as oil gets centrifuged away from it.

To test the 1st problem disconnect the clutch cable at the operating lever on the engine case. Check for play in the shaft.

The release bearing can only be properly checked with the clutch cover taken off. But if the clutch isnt releasing properly, this has to be a suspect.

If you need to fit a new release bearing use a thrust washer either side of the rollers and plenty of grease

[bobh]

When I got my current 600 the needle rollers had gone as described by CD. It was very obvious from the sideways play in the spçndle that there was a problem. but even then the clutdch was freeing fairly well.

I think the parts cost me about 40 quid (spndle, bearing, seal and cover gasket).

[davies2619]

A quick update:

The problem turned out to be seized plates. After stripping the clutch and separating/cleaning the plates the clutch now works fine:-)

Thanks for all the advice