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I recently replaced the clutch plates (steels and friction plates) and the clutch cover gasket on my 1981 yamaha xs400 H (special 2), and now I have lost all resistance in my kickstarter. I can push it all the way through by hand with very little effort. After replacing the plates, i reassembeled the clutch exactly as it had been before, then replaced the gasket and refilled the oil. Before I took apart the clutch, the bike started up and ran. The plugs are fresh, and the electric start sounds right except the engine does not start up. I had a similar problem like this before and i was able to fix it by loosening the clutch cable tension at the handlebars. I tried that and still no luck. Does anybody have any idea what could be wrong? If so, any ideas on how to fix it?
Thanks,
Jason

can the bike be rolled when you put it in gear and release the clutch lever?

Thanks for responding. I haven't had much of a chance to work on it latley, but i'll try rolling it later this week. Also, does anybody know of a trick to remove covers without ripping gaskets? I had to use gasket cement when i replaced my clutch cover gasket (there were a few knicks in the metal) and i would like to open it up again, but i'm afraid that if i do the gaskety might rip. Any ideas?

Thanks,
Jason

I finally had some time today to work on the bike, and yes the bike can be rolled when it is in gear with the clutch out. I also tried starting it with the clutch adjustment screw all the way out, and with it all the way in. Neither way changed anything.

Strange. Sounds like the plates are not engaging. Usually after a clutch job, if you made a mistake the results are often the opposite. The clutch plates stay engaged and you can't release them. At least this explains why your kickstarter doesn't work.

I think you're going to have to pull the assembly apart again and see what went wrong. Double check that you have the right number and size plates and that they're facing the right way. Also check the springs in the basket. They should be holding the clutch engaged in it's normal position.

Keep at it. The first clutch I ever replaced was on a Yam XS750 triple. It took 2 days and 4 or 5 disassemblies to figure it out.

Did you readjust the clutch cable after reassambly???

Last weekend I took the clutch apart again and reassembled it. While I was reassembling the clutch, the kickstart gear slipped out and I put it back together as per my shop manual. I also recharged the battery. After I put it back together, i was able to get the bike started through the electric starter. The kickstarter still had zero resistance though. I took the bike around block a few times and filled up the gas tank, but the bike still had no power to it and it was a struggle to get it up to 12mph. Any ideas? This bike is driving me nuts.

Jason

i also tried adjusting the clutch cable a hundred different ways and i don't think that it changed anything.

Is the engine revving high rpm? If not your problem may be with lack of enough fuel to the carbs.