XT660 4MY clutch
 

Just stripped my clutch, the bike had all the symptons of the plates stuck together (bikes been stood for 7 years).... anyway the plates separated really easy, everything looks good...well apart from the release bearing which fell to bits....anyone got any ideas...

Symptoms were, clutch not disengaging even when pushing bike in gear.
Start engine, select gear ... bike would stall.

Cable etc... all working & adjusted

I could bet you that your problem is the sidestand switch has gone wrong!

Or, when you dissasembled the clutch you forgot to re-adjust the "butterfly" nut that regulates the clutch!
Plus, set the clutch lever on-the-fly adjuster to around middle position and leave some very small gap on that "butterfly" clutch nut because when you reassemble the engine case and fill it up with oil, it will "tighten" the clutch a bit!
This could be your problem!

It took me a couple of tries to make it work perfect on my XT600E!

Vando :cool4:

Hmmm... the clutch wasn't working when I bought it... I thought the plates were stuck together.
Stripped it down & they aren't.
Clutch wasn't disengaging...

How could the sidestand switch cause it?

I haven't reassembled it yet, just took it to bits...

ah just thought... you were thinking the engine was cutting out when I selected a gear.... sidestand switch.
No its not that its actually going into gear & stalling... if I revved the engine enough it would wheelie away :rolleyes2:

That suggests you have an internal issue that you need to sort. most likely part of the actuator mechanism is not doing its job as it should.

I would start with a service manual, and begin examining your clutch actuator system.