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I just got a new clutch cable for my 1980 yamaha xs 400 special because i just put cafe bars on and i made it work and fit but now i cant get the clutch to engage. iv tried adjusting it with the skrew on the lever but it won't adjust it enough. is there anyone who had an idea of what to do?
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You will need to remove the alternator rotor(LH side of the engine) which requires a special tool. You can attempt to bribe your local Yamaha service centre mechanic but I doubt you'll have much luck. Using a gear puller is not recommended as it could damage the rotor. The correct tool screws into the middle of the rotor to seperate it from the crankshaft.
The starter clutch needs to be replaced. At the other end of that chain is a wheel with a couple slots cut at angles. Inside each of these slots is a small cylindrical piece of metal. The whole unit fits over the end of the crankshaft and because of the angle of the slots those cylindrical pieces of metal (which move freely in the slots) will be forced against and grip the crankshaft when the starter is operated. If they become worn down they are no longer able to exert enough pressure on the crankshaft in order to turn it. Buying a starter clutch 2nd hand is not recommended. If you are unable to source one from a bike shop, try and have them made. Take the old ones to an engineering shop. Unless you know how to temper/harden metal of course.
if the last digit on your spark plug is a 8 then it would be .032 if its a 9 then .036, 10 =.040. But if you buy your spark plugs new they should all come pre-gaped.
my gess is you have the throtle cable to tight and the cluch cable is crossing over it,,,so every time you dip the cluch it opens the throtle as well by pressing on the throtle cable,,, its common for this to happen
check all your cables and if you need to to stop it happening again tape them together,,,,
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