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Quick clutch push lever screw question Quick clutch push lever screw question
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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
Photo by Alessio Corradini, on the Salar de Uyuni, Bolivia, of two locals

I haven't been everywhere...
but it's on my list!


Photo by Alessio Corradini,
on the Salar de Uyuni, Bolivia,
of two locals



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  #1  
Old 14 May 2019
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Quick clutch push lever screw question
Just a quick one, hopefully

Can anyone tell me whether this screw really has a washer?



Reason I'm asking:

1) I can't find it, and the screw already has some sort of washer built-in:



2) When I turn the screw it basically stops the push lever from turning? Like a stopper.

I'm a bit confused about the exact function of this screw? What is it for?

I can't find any info in the manual regarding this screw, except that you have to put it to 12nm.

Thanks
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  #2  
Old 14 May 2019
dzl dzl is offline
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Yes...it is actually a thick copper washer to provide a good seal as can leak oil if not. i would say is going in too deep without the copper washer and hitting shaft?
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  #3  
Old 14 May 2019
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Quote:
Originally Posted by dzl View Post
Yes...it is actually a thick copper washer to provide a good seal as can leak oil if not. i would say is going in too deep without the copper washer and hitting shaft?
That's what I'm thinking. However in that case, what is the purpose of this screw? To prevent wobble of the clutch push lever or something?
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  #4  
Old 14 May 2019
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prevent part 21 from sliding up.
indeed, if it binds the shaft it's because a sealing copper washer is missing.
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  #5  
Old 14 May 2019
dzl dzl is offline
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It locks the push lever shaft so that it cant move up once you have installed it. When you install the screw it sits in the bottom part of shaft and not allowing shaft to ride up,
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Old 14 May 2019
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Quote:
Originally Posted by turboguzzi View Post
prevent part 21 from sliding up.
indeed, if it binds the shaft it's because a sealing copper washer is missing.
Ah I see, that makes sense.. it falls in the smaller/slotted part of part 21. Thanks.

Now I'm on the subject of weird screws...

There's another weird one that I can't find on any of the exploded diagrams or in the manual, the one that goes here:



Don't have a pic of it now (and can't find it online), but basically it's a screw with another screw in it, like the clutch adjuster.
It looks like it presses against the geardrum or something? I'm not sure.



Looks like it comes in here, very close to the drum.

Thanks
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  #7  
Old 14 May 2019
dzl dzl is offline
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Neutral switch goes in there
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Old 14 May 2019
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Quote:
Originally Posted by dzl View Post
Neutral switch goes in there
Aah... that's why I couldn't find it. It's under electrical 2.
It grounds itself on a piece of the drum, I'm guessing?



What about the screw? Special way to adjust it? You turn it in until the neutral light lights up ?
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  #9  
Old 14 May 2019
dzl dzl is offline
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No...no adjustment, there is a wire that goes to that screw...normally blue in colour. Just screw neutral switch all the way in. Wire is in the stator loom. There is a long slot in the stator/ flywheel crankcase cover for that wire to come out from the inside of engine to the neutral switch
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Old 14 May 2019
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Quote:
Originally Posted by dzl View Post
No...no adjustment, there is a wire that goes to that screw...normally blue in colour. Just screw neutral switch all the way in. Wire is in the stator loom. There is a long slot in the stator/ flywheel crankcase cover for that wire to come out from the inside of engine to the neutral switch
Right, bit the pin at the end is touching something in on the gear drum right (at least when it's in neutral)? At least that's how the neutral switch on my other bike works.. it looks very different.
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Old 14 May 2019
dzl dzl is offline
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Yep there is a screw in the end of the drum that operates switch. You can see the screw on the parts pic of the shift drum itself

Have you got the rest of bike assembled? Close to getting it going? Should be good!
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Old 14 May 2019
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Quote:
Originally Posted by dzl View Post
Yep there is a screw in the end of the drum that operates switch. You can see the screw on the parts pic of the shift drum itself

Have you got the rest of bike assembled? Close to getting it going? Should be good!
Ah, yeah I saw that screw in search of this one. That makes sense, thanks!

State of engine: added clutch



State of bike:

Stripping it...



Carb is already rebuilt. New airfilter ready. When the engine is done i'll add it to the frame with only the basics and see what happens.

Engine top-end was hardlocked/top-end destroyed when I bought it, so never seen it run.

Next step, piston
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Old 14 May 2019
dzl dzl is offline
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Nice..... I should have made an engine stand long ago like you have. Would have saved a lot of handling dramas. I would like to add a 3AJ to my stable but its slim pickings here in oz even trying to find a restorer bike. Hard to come by anything.
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  #14  
Old 20 May 2019
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More weird stuff....

This guy



Mine doesn't come with it - at least I can't find it.

Also, this guy doesn't seem to put them on:

https://www.youtube.com/watch?v=q95R4Drw_1U

2:10 and 13:50

Nut doesn't appear to be hitting the thread (bottoming out?) so now sure what the deal with this washer is?
From pictures it appears to be way thicker than regular washers.

Thanks
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  #15  
Old 21 May 2019
dzl dzl is offline
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Yes they are thick. Dimensions of a spare I have are 11mm ID x 18mm OD x 5mm thick black steel
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