xs650 clutch locking up

Hello, I was helping a friend yesterday with his xs650. I'm pretty new to Japanese bikes.
I swear we got the washers all installed correctly,we checked 50 times, but as soon as I put only one spring bolt on the pressure plate it totally locks everything up.

Even just by pressing the plates with my fingers it tightens up everything significantly.

Kicker, basket , hub etc...
I made sure the washer that was omitted in the book was installed too.
I did notice that where the book calls for a conical washer, his was flat.
maybe he crushed it?

Not sure, hopefully someone can help him get on the road. the bike runs good, and he's spent way too much time on it and is at his wit's end.

Thanks in advance.

What year is the clutch?

They made 3 types; early 6 disc without spring loaded boss, 7 disc without spring loaded boss, then finally back to 6 disc w the spring loaded boss. You have either the 7 disc or the late model 6 unless you have an early model XS. None of this really matters unless you're jamming 7 plates in a 6 plate unit. I don't see how you wouldn't catch this though....

Here's the order of the hardware. Often times people get the first two washers to go on backwards. The smaller one w the red dot is the first bit to go on the motor when reinstalling the clutch:



Once all that's on the clutch nut gets torqued to 55lbs. You'll need a holding tool to R/R the clutch.

Do you have a complete understanding as to how the clutch works? The outer basket will not spin freely since it meshes to the crank. The inner boss spins freely provided the bike is in neutral. If you have the plugs in, forget trying to sping the outer basket by hand at all.

Also remember to line up the dots on the clutch boss and the pressure plate:




Awesome link:

http://thexscafedotcom.wordpress.com...utch-assembly/

shit man, thanks alot.
both of our thin washers were the same.
we were mixing parts from two bikes.
the picture with the dots finally set it all straight.
can't thank you enough!

No problemo dude.

They upgraded the boss bearing, btw. May think ab replacing it while you're in there. Supposedly helps find neutral better:

http://www.mikesxs.net/product/39-6505.html

Also a good opportunity to replace the shift springs:

http://www.mikesxs.net/product/05-0039.html
http://www.mikesxs.net/product/05-0040.html

It's like $30 worth of shit and an extra 5 minutes, and it makes a big difference. You can also check the shifter adjustment while you're back there.

Make sure to check your clutch pushrod. If it's 2 piece upgrade to 1 piece. Make sure you have the ball bearing that goes with it. It's all in that link^

Also, you probably already checked, but make sure the cush springs on the back of the basket are all intact.