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SECTION H:
CLUTCH/TRANSMISSION/DRIVETRAIN:
XJ1100 and XS1100 engines:
Clutch Rebuild Kits:
We’ve put together the typical components you’ll need to properly rebuild your clutch into our CLUTCH REBUILD KITS, which will save you the time and effort to sort thru all the various part components and choices. Available as either BASIC or COMPLETE rebuild kits, with additional options for STANDARD or HIGH-PERFORMANCE components, we’ve got you covered no matter how abused your original clutch has become.
BASIC CLUTCH REBUILD KITS contain at least the following items:
- clutch cover gasket
- full set of the clutch springs and their retaining bolts
- full set of primary friction discs
COMPLETE CLUTCH REBUILD KITS contain at least the following items:
- everything included in the basic rebuild kits, and…
- full set of the primary drive plates
- the clutch boss drive plate and its retaining ring
- the actuating shaft return spring
- the pivot axle shaft oil seal, return spring, cotter pin, and screw housing o-ring
- the special clutch drum lockwasher
In either of the above kits, You also have the choice of standard or hi-performance components:
STANDARD kits contain OEM or oem-level components.
PERFORMANCE kits contain upgraded cover gaskets, hi-performance clutch springs, and high-performance friction discs and, in the complete clutch kits, high-performance metal drive plates.
Of course, for the do-it-yourselfer, we also have all of the individual components available a-la-carte and listed further below. Either way, we’ve got everything you’ll need in the clutch.
HCP23399 Aftermarket BASIC CLUTCH REBUILD KIT with STANDARD PERFORMANCE COMPONETS, for all XJ1100 and XS1100 models. Contains a standard-duty clutch cover gasket, a full set of the standard duty pressure plate springs and bolts, and a full set of standard-duty friction discs.
$ 149.95
HCP23422 Aftermarket BASIC CLUTCH REBUILD KIT with HIGH-PERFORMANCE COMPONETS, for all XJ1100 and XS1100 models. Contains a “leak-proof” high-performance clutch cover gasket, a full set of the heavy-duty pressure plate springs and bolts, and a full set of high-performance friction discs.
$ 209.95
HCP23400 Aftermarket COMPLETE CLUTCH REBUILD KIT with STANDARD PERFORMANCE COMPONETS, for all XJ1100 and XS1100 models. Contains everything in the HCP23399 standard-duty basic clutch kit above, along with the clutch boss primary drive plate and its retaining ring, a full set of standard-duty main clutch pack metal drive plates, the special clutch drum lockwasher, the actuating shaft oil seal, return spring, cotter pin, and screw housing o-ring.
$ 279.95
HCP23423 Aftermarket COMPLETE CLUTCH REBUILD KIT with HIGH-PERFORMANCE COMPONETS, for all XJ1100 and XS1100 models. Contains everything in the HCP23422 hi-po basic clutch kit above, along with the clutch boss primary drive plate and its retaining ring, a full set of high-performance main clutch pack metal drive plates, the special clutch drum lockwasher, the actuating shaft oil seal, return spring, cotter pin, and screw housing o-ring.
$ 319.95
Clutch Cover Gasket:
ec4) OEM CLUTCH COVER GASKETS. A must-replace item anytime you remove the clutch cover (right side of the bike) for periodic cleaning or clutch plate adjustment, repair, or replacement.
OEM clutch cover gaskets are made from a standard duty, graphite impregnated paper material. We recommend the use of the aftermarket hi-performance paper gaskets which are designed to slightly swell in the presence of petroleum products (fuel or oil), thus creating a super-tight, leak-proof flange seal.
HCP1027 OEM main clutch cover-to-block standard duty paper GASKET, for all XJ1100 and XS1100 models.
$ 28.95
HCP18429 Aftermarket clutch cover-to-block hi-performance GASKET, for all XJ1100 and XS1100 models.
$ 29.95
And while you have the cover off, now would be the time to replace the oil level “gauge” window in your clutch cover if it is cloudy:
HCP1039 OEM clutch cover OIL LEVEL GAUGE. This is the clear sight window at the bottom front of the clutch cover that allows you to see the engine oil fluid level. You must remove the clutch cover itself in order to replace this item. Includes the rubber seal. Fits all XJ650, XJ700, XJ750, XJ900, XJ1100, and XS1100 models.
$ 32.95
HCP18944 Aftermarket clutch cover OIL LEVEL GAUGE. This is the clear sight window at the bottom front of the clutch cover that allows you to see the engine oil fluid level. You must remove the clutch cover itself in order to replace this item. Includes the rubber seal. Fits all XJ650, XJ700, XJ750, XJ900, XJ1100, and XS1100 models.
$ 24.95
Clutch Pressure Plate Pushrod Actuating Shaft and Parts:
The pushrod actuating shaft emerges from the clutch cover and is what the clutch cable is attached to and acts upon. Although it rarely wears out, some of the operating parts can become worn and should be inspected carefully and renewed during a major clutch overhaul, as well as the oil seal where the shaft emerges from the clutch cover.
HCP2109 OEM clutch pressure plate actuator shaft NUT. Fits all XJ1100 and XS1100 models. Each:
$ 4.95
HCP28541 Aftermarket clutch pressure plate actuator shaft NUT. Made from a bright zinc-plated alloy steel. Fits all XJ1100 and XS1100 models. Each:
$ 1.95
HCP28539 Aftermarket clutch pressure plate actuator shaft NUT. Made from a bright 18/8 stainless steel. Fits all XJ1100 and XS1100 models. Each:
$ 2.95
HCP28540 Aftermarket clutch pressure plate actuator shaft NUT. Made from a black-oxide coated 18/8 stainless steel. Fits all XJ1100 and XS1100 models. Each:
$ 3.95
HCP4629 OEM clutch pressure plate actuator shaft FLAT WASHER. Fits all XJ1100 and XS1100 models. Each:
$ 2.95
HCP12738 OEM clutch pressure plate actuator shaft PIVOT ARM. Fits all XJ1100 and XS1100 models. Each:
$ 21.95
HCP12739 OEM clutch pressure plate actuator shaft CLEVIS JOINT. Fits all XJ1100 and XS1100 models. Each:
$ 7.95
HCP12749 OEM clutch pressure plate actuator shaft pivot arm-to-clevis joint PIN. Fits all XJ1100 and XS1100 models. Each:
$ 8.95
HCP12750 OEM clutch pressure plate actuator shaft pivot arm-to-clevis joint COTTER PIN. Fits all XJ1100 and XS1100 models. Each:
$ 2.95
HCP23593 Aftermarket clutch pressure plate actuator shaft pivot arm-to-clevis joint COTTER PIN. Fits all XJ1100 and XS1100 models. Each:
$ 1.95
HCP12751 OEM clutch pressure plate actuator shaft pivot arm RETURN SPRING. Fits all XJ1100 and XS1100 models. Each:
$ 4.95
HCP12752 OEM clutch pressure plate actuator shaft OIL SEAL. Fits all XJ1100 and XS1100 models. Each:
$ 9.95
HCP18150 Aftermarket clutch pressure plate actuator shaft OIL SEAL. Fits all XJ1100 and XS1100 models. Each:
$ 7.95
HCP12736 OEM clutch pressure plate actuator shaft PUSH SCREW. Fits all XJ1100 and XS1100 models. Each:
$ 39.95
HCP12737 OEM clutch pressure plate actuator shaft ADJUSTER SCREW. Fits all XJ1100 and XS1100 models. Each:
$ 12.95
HCP12734 OEM clutch pressure plate actuator shaft push screw HOUSING. Fits all XJ1100 and XS1100 models. Each:
$ 23.95
HCP12747 OEM clutch pressure plate actuator shaft push screw housing DOWEL PIN. Fits all XJ1100 and XS1100 models. Each:
$ 3.95
HCP12735 OEM clutch pressure plate actuator shaft push screw housing BALL RETAINER. Fits all XJ1100 and XS1100 models. Each:
$ 11.95
HCP12748 OEM clutch pressure plate actuator shaft push screw housing O-RING. Fits all XJ1100 and XS1100 models. Each:
$ 2.95
HCP21662 Aftermarket clutch pressure plate actuator shaft push screw housing O-RING. Fits all XJ1100 and XS1100 models. Each:
$ 1.95
Clutch Pressure Plate:
This is the outer "cover" plate that you actually first see when you remove the side cover from your engine....the compression springs and bolts fit into this plate. It rarely needs replacing, but if it cracked, warped, or has broken edges, it's time for a replacement........
HCP3240 OEM clutch PRESSURE PLATE fits all XJ1100 and XS1100 models. Each:
$ discontinued
HCP12743 OEM clutch PRESSURE PLATE BEARING fits all XJ1100 and XS1100 models. Each:
$ 21.95
Clutch Pressure Plate Compression Springs and Bolts:
As mentioned earlier, these springs wear after time and should ALWAYS be replaced as part of a clutch rebuild. And the factory recommends that the spring retaining bolts always be replaced and not be re-used.
HCP3241 OEM clutch pressure plate COMPRESSION SPRING, use 6 per clutch on all XJ1100 and XS1100 models. Each:
$ 8.95
HCP3241SET6 OEM clutch pressure plate COMPRESSION SPRINGS, set of 6:
$ 49.95
HCP10985 Aftermarket clutch pressure plate COMPRESSION SPRINGS SET, high-performance increased-rate spring provides approximately 10% greater force than original springs, and are "pre-fatigued" so that you'll get the same performance after 5,000 miles of use as you did in the first 50 miles. Complete set of 6 springs for use on all XJ1100 and XS1100 models. Each:
$ 39.95
HCP3197 OEM clutch pressure plate compression spring FLANGED BOLT. Fits all XJ550, 1984-85 FJ600, 1984-91 XJ600 Euro, 1986-88 FZ600, 1986-90 YX600 Radian, XJ650, all 1981-83 XJ750 models, XJ750-D, XJ900RK and RL models, XJ1100, and XS1100 models; use 5 per clutch on all models except XJ1100 or XS1100 models, which use 6. Each:
$ 2.50
HCP3197SET6 OEM clutch pressure plate compression spring BOLTS, set of 6:
$ 13.95
HCP21306 Aftermarket clutch pressure plate compression spring FLANGED BOLT. Fits all XJ550, 1984-85 FJ600, XJ650, all 1981-83 XJ750 models, XJ750-D, XJ900RK and RL models, XJ1100, and XS1100 models; use 5 per clutch on all models except XJ1100 or XS1100 models, which use 6. Each:
$ 1.50
HCP21306SET6 Aftermarket clutch pressure plate compression spring BOLTS, set of 6:
$ 8.50
Clutch Friction Discs:
HCP3238 OEM clutch PRIMARY FRICTION DISC, hard cork material discs provide the grab and the go for your clutch. Brand new replacements prevent clutch slippage and return the original performance to your clutch. Fits all XJ1100 and XS1100 models, use 8 per clutch. Each:
$ 13.95
HCP3238SET8 OEM clutch PRIMARY FRICTION DISCS, set of 8:
$ 99.95
HCP1643 Aftermarket clutch PRIMARY FRICTION DISC, hard cork material discs are an oem-replacement quality and material. Fits all XJ1100 and XS1100 models, use 8 per clutch. Each:
$ 11.95
HCP1643SET8 Aftermarket clutch PRIMARY FRICTION DISCS, set of 8:
$ 87.95
HCP10983 Aftermarket clutch PRIMARY FRICTION DISC is made from a high-performance Kevlar material for the ultimate in street performance! Fully segmented design insures the greatest coefficient of friction and durability. Fits all XJ1100 and XS1100 models, use 8 per clutch. Each:
$ 21.95
HCP10983SET8 Aftermarket clutch PRIMARY FRICTION DISCS, set of 8:
$ 149.95
Clutch Drive Plates:
HCP3239 OEM clutch PRIMARY DRIVE PLATE, stamped, etched steel discs provide the friction surface necessary for the friction discs to have something to grab onto. Brand new replacements prevent clutch slippage and return the original performance to your clutch. Fits all XJ1100 and XS1100 models; use 7 per clutch. Each:
$ 13.95
HCP3239SET7 OEM clutch PRIMARY DRIVE PLATES, set of 7:
$ 89.95
HCP10984 Aftermarket main clutch pack PRIMARY DRIVE PLATE is made from a heat-tempered #2 grade steel which both minimizes disc warpage (no more "chattering" clutch!) and insures maximum plate rigidity and friction via the surface design features. Fits all XJ1100 and XS1100 models; use 7 per clutch. Each:
$ 8.95
HCP10984SET7 Aftermarket main clutch pack PRIMARY DRIVE PLATES, set of 7:
$ 59.95
Clutch Drum and Basket:
The "outer basket" is actually known as the PRIMARY DRIVEN GEAR and is the largest part in your clutch system. This part rarely needs replacement and is not normally removed during a typical clutch "service procedure"----meaning a clutch friction disc and drive-plate replacement procedure----unless the splined "fingers" (which accept the friction plate outer "tabs") become fractured or broken.
You should, however, carefully inspect along the edges of the slots where the friction plate tabs engage in this basket, and remove and sharp or rough edges to insure the chatter-free operation of your discs.
Likewise with the clutch drum, or what is technically described as the CLUTCH BOSS, (or the "inner basket") and which the teeth of the metal drive plates engage with. Again, normally this cast aluminum piece does not need replacing, although it's always a good idea to inspect and smooth the edges of the slots where the drive plate teeth engage.
Outer Clutch Basket Parts:
HCP12727 OEM clutch primary drive gear THRUST PLATE WASHER, for all XJ1100 and XS1100 engines. This is the washer that fits on the outside of the drum.
$ 11.95
HCP12733 OEM clutch primary drive gear THRUST PLATE WASHER, for all XJ900 S/SH, XJ1100, and XS1100 engines. This is the washer that fits on the inside of the drum.
$ 8.95
Inner Clutch Hub:
HCP12741 OEM clutch CLUTCH BOSS PRIMARY DRIVE PLATE, stamped, etched steel disc provide the friction surface necessary for the friction discs to have something to grab onto. Brand new replacement prevent clutch slippage and allow the maximum performance from your bike. This drive plate is the one that fits closest to the clutch boss hub (at the very "bottom" of the stack). Use 1 per clutch. Fits all XJ1100 and XS1100 models.
$ 21.95
HCP12742 OEM clutch boss drive plate RETAINING RING, for all XJ1100 and XS1100 engines.
$ 13.95
HCP12744 OEM clutch hub RETAINING NUT. Fits all XJ1100 and XS1100 models. Each:
$ 8.95
HCP13247 Aftermarket clutch hub RETAINING NUT. Fits all XJ1100 and XS1100 models. Each:
$ 7.95
HCP12745 OEM clutch hub SPRING WASHER. Fits all XJ1100 and XS1100 models. Each:
$ 7.95
HCP13246 Aftermarket clutch hub retaining nut LOCK WASHER. Fits all XJ1100 and XS1100 models. This washer should never be re-used and always be replaced when it is removed. Each:
$ 7.95
CLUTCH SYSTEM TOOLS:
NOTE: SOME OF THE FOLLOWING TOOLS ARE AVAILABLE FOR RENTAL!!: some tools are a one-time or infrequent use tool, so it may be more economical for you to rent them from us, rather than to purchase outright. Please see the “rental” section within the THE TOOLBOX section of our catalog at:
http://xjbikes.com/forums/index.php?threads/xj-parts-catalog-section-p-the-toolbox.44630
and review the availability and procedures in the TOOL RENTAL section.
NOTE: if the threaded holes in the engine case have minor damage, they can be easily salvaged with a thread-chaser/tap:
HCP2399 Aftermarket THREAD CHASER AND CLEAN-UP TAP, made from a high-speed titanium nitride coated steel. For the following threaded holes listed below, as well as many other areas of the bike. This 6 x 1.00 pitch is a very common sized thread.
$ 9.95
- Hitachi HSC32 air compensator jet holes.
- Hitachi lower carb rack mount screw holes.
- Hitachi pilot and main air jets port holes (in carb throat, below vacuum piston).
- Hitachi carb bowl drain screw hole.
- Mikuni XJ550, FJ/FZ/YX600, XJ600 Seca Ii, XJ650 Turbo, XJ700-X, XJ750-X, XJ900, XJ1100, and XS1100 lower carb rack bracket screw holes.
- All models: gas tank mounting holes for the petcock.
- All models: gas tank fuel sending unit mounting holes.
- All XJ550 - XJ900 models cylinder head exhaust port stud holes.
- All XJ550 - XJ1100 models cylinder head valvecover mounting bolt holes.
- All XJ550 - XJ1100 and XS1100 models cylinder head cam bearing cap bolt holes.
- All XJ550 - XJ1100 and XS1100 models cylinder head intake manifold bolt holes.
- All XJ550 - XJ1100 and XS1100 models cylinder head valvecover mounting bolt holes.
- All XJ550 - XJ1100 and XS1100 models engine side covers mounting bolt holes.
- All XJ550 - XJ1100 and XS1100 models engine oil pan mounting bolt holes.
- All XJ550 - XJ1100 and XS1100 models engine upper-to-lower crankcase cinch bolt holes (note: some of the mounting holes are different size, and require the use of the larger HCP11028 tap below).
- XJ700-X and XJ750-X cylinder heads and jugs coolant jacket bolt holes.
- Some models: cylinder head cam chain tunnel-to-cylinder jugs cinching studs, for engines that have 2 studs on both the front and rear of the tunnel (models with a single tunnel stud use the HCP11028 tap listed further below).
- Most models: upper crankcase to cylinder jugs stud.
- All models: cam chain tensioner mounting bolt holes.
- Some models: mechanical tachometer drive housing mounting hole.
HCP28170 Aftermarket thread tap or EZ-out extractor TAP HANDLE, featuring offset tap handles and fully adjustable head for all m3-m12 size taps and size 0 to ½” extractors. This is the proper way to hold a tap or extractor to insure that the force is directed straight down and doesn’t “wobble” as you are cutting, reaming, or extracting. Much better than using pliers or vise-grips to hold the tool……..
$ 17.95
NOTE: always use a proper thread-cutting oil or lubricant before using thread taps! Thin motor oils work fine when merely doing a "clean-up" thread chase; a real cutting fluid should be obtained if a threaded bore needs to be truly cut:
HCP2402 Aftermarket machinist-grade professional THREAD CUTTING FLUID, for use when cutting into aluminum or other soft metal. 4-ounce non-aerosol can.
$ 8.95
HCP2403 Aftermarket machinist-grade professional THREAD CUTTING FLUID, for use when cutting into steel or other ferrous metals. 4-ounce non-aerosol can.
$ 8.95
HCP9237 Aftermarket clutch drum HOLDER TOOL. In order to install the clutch drum retaining nut HCP3204 above, you have to lock the clutch drum and prevent it from turning while the nut is torqued. Fits use with all XJ-series bikes. High quality, professional grade tool will last a lifetime.
$ 49.95
HCP10543 Aftermarket clutch drum HOLDER TOOL. In order to install the clutch drum retaining nut HCP3204 above, you have to lock the clutch drum and prevent it from turning while the nut is torqued. This tool uses a re-cycled drive plate to hold the basket while the nut is being removed or installed, thus spreading the load more evenly and equally than the HCP9237 tool listed above. Light-duty design is not recommended for shop use, but it works just fine for periodic (individual) use. Fits all XJ550, XJ650, XJ700, XJ750, and XJ900 models.
$ 29.95
HCP10530 Aftermarket standard-depth 30mm SOCKET, 1/2"-drive thick-wall impact socket necessary to remove or install the HCP3204 clutch hub nut. Black, 6-point, 1-/2" drive.
$ 13.95
HCP10300 Aftermarket 3/8"-to-1/2" DRIVE ADAPTER. For use with the HCP10298, HCP10299, HCP10530, HCP11336, HCP22025, or the HCP22947 sockets, and the 10mm and 12mm HCP10302 stud extractors included in the HCP10301 tool kit. Most people have the standard 3/8" drive ratchet wrenches in their tool kits already, and the larger 1/2" drive sockets can be used with those ratchets with this converter/adapter. Chrome-plated, 1/2" male drive, 3/8" female receiver.
$ 12.95
Gasket Adhesives and Removers:
b4) Aftermarket pure SILICONE GREASE----this is the proper product to use when installing any rubber-based o-ring or seal or paper gasket. Silicone doesn't affect rubber, provides good seal lubrication, can also be used as a "glue" to hold gaskets and seals in place during installation, and to aid in the re-assembly of components.
HCP28407 Aftermarket o-ring, oil seal, and gasket installation pure SILICONE GREASE. This small 5-gram (1/6-oz) snap-open "pillow packet" is enough for a few small oil seals, dozens of o-rings, and the like. Each:
$ 4.95
HCP1714 Aftermarket o-ring, oil seal, and gasket installation pure SILICONE GREASE. This generous 14-gram (1/2-oz.) tub goes a long way, because just like Brylcreem, "just a little dab will do ya'!" Each:
$ 9.95
HCP3120 Aftermarket black GASKET MAKER, large family-sized 3.8 ounce squeeze tube. Enough to do about a few dozen gaskets! I'm sure it works well in other applications. This is for use on the half-moon end plugs (HCP1619 for non-YICS applications) and the molded-in end plugs (part of the actual rubber gasket) on YICS engines. Do not use on the paper or rubber valvecover gasket itself! Each:
$ 11.95
HCP3120A Aftermarket black GASKET MAKER, smaller 1/2-ounce squeeze tube. Enough to do a few gaskets! It's the smallest size offered. I'm sure it works well in other applications. This is for use on the half-moon end plugs (HCP1619 for non-YICS applications) and the molded-in end plugs (part of the actual rubber gasket) on YICS engines. Do not use on the paper or rubber valvecover gasket itself! Each:
$ 7.95
HCP25092 Aftermarket high-performance aviation-grade, black, non-hardening GASKET MAKER, 1.5 ounce squeeze tube. This special high-performance sealant is ideal for use on engine case covers as a “problem solver” material which will compensate for poor machining tolerances or the slight warpage that can occur over time on precision-fit pieces. A very thin film of this material is all that is needed! Each:
$ 8.95
Torque Wrenches:
hks12) Yep, a TORQUE WRENCH sure can be a pain to use, especially in tight, cramped spaces, and so their use is one the easiest ways to tell a professional mechanic from a wanna-be. The proper torque values for a fastener were not determined by whim-and-fancy, but by engineering principles and mechanical fastener requirements. All it takes is one fastener snapping or stripping out of a threaded aluminum case, and you'll find that the cost and use of an accurate torque wrench is "cheap" compared to the cost of solving the problem!
HCP9972 Aftermarket precision CLICKER TORQUE WRENCH, 3/8" drive head, 20-200 inch-pounds (1.5 to 16 foot pounds), ratchet head and handle made of hardened steel for accuracy and durability. Scale is marked in both metric and SAE torque values for convenience. Comes in a plastic storage case. A good quality, affordable torque wrench for small fastener, low-torque applications. NOTE: please resist the temptation to "cheat" on low-value torque fasteners by using a high-value torque wrench (like the HCP9973 below) to set such fasteners. Torque wrenches, by their design, are only accurate within a certain range of torque values, and totally inaccurate above and below their designated range of values.
$ 69.95