Clutch tension from cover

[kaicay1]

I have been having an issue where if I am to tighten my sprocket cover/clutch housing all the way down it completely disengages the clutch. I am left with having to back out the bolts until tension is enough, is there a spacer or something required in between the cover and block? Or is this how it is supposed to function?

I have a 1981 Yamaha xs400sh

 

[kaicay1]

 

[CaptChrome]

Welcome to the forum.

is there a spacer or something required in between the cover and block? Or is this how it is supposed to function?

No to both questions. There is a clutch free play adjustment that you make from the outside of the cover. It sounds like you have no free play in the clutch throw and need to back off of the adjuster.

 

[bafana445]

this looks nice

 

[avemachina]

What a beautiful bike and a beautiful place!

First, on the clutch lever up top, screw it all the way in until it touches the bar. Now on the engine side--if you took off your clutch cover, pop it back on and look for a black rubber plug. Pry it out with a flathead or whatever. There's a Phillips-head screw with a locknut--that's the adjuster. The first two posts here have great photos:

https://www.xs400.com/threads/1978-xs400-clutch-adjustment.20630/

And here's the procedure:
https://www.xs400.com/threads/clutch-push-rod-bearing-question.11658/post-120532

My suspicion is that your adjuster screw is too far in at the engine. Mechanically, there's a little ball bearing between that screw and the clutch rod--when you pull the lever, it rotates a spiral gear and pushes the ball-bearing into the rod. The screw with the locknut dictates how deep the BB sits when you aren't pulling the lever. I'm betting yours is too far in because the "default" BB position doesn't give you enough room to fit the pushrod into the BB channel.

I've done a quick diagram that can hopefully help guide you on what needs to be done.