I was wondering if any you has had the following experience.
The clutch does not fully release and is causing problems when shifting gears. When the engine is cold this is less of a problem than when it is hot. I have checked the clutch springs and removed the washers underneath to loosen the clutch pressure. This has improved the problem slightly. I was afraid this would result in a slipping clutch, but is doesn't.

Another way of describing the problem is that when the engine is hot and running free and when I select first gear, the bike feels like it is moving forward and I cannot get back into neutral gear without switching off the engine.
I have cross checked the travel distance of the clutch mechanism in the left side engine cover with my other (working fine) XV920 and it is roughly the same, between 1,8 to 1,9 mm. Does anyone have a smart idea what can be causing this issue?

Update! I have tried to change the oil, as some of you mentioned that mineral vs synthetic oil could make a difference. No real result.
Tonight I will remove the clutch housing incl rotor and check for any damage that could result in friction plates getting stuck resulting in the problem I am having. According to the tech manual when these damages are removed the friction plates should be able to move freely again. fingers crossed, that hopefully this will have the right effect.
I will keep you updated.

SOLVED! It has done the trick. Took me about 2 hours of filing. Especially the clutch housing had some damage. Just had my testrun, it works like new. :) ;D

Thats unusual. My clutch housing was like new, at about 100.000 kms.

Gruss,
Georg

The engine has done approx 120.000. The last few years we started to have trouble getting the bike into neutral when it was running and standing still, this continued until we had serious issues with changing gears. The clutch housing had little dimples from the plates. After filing them out the bikes running well again, even shifting into neutral when standing still works again. I found the tip to look for damage in the clutch housing in the workshop manual from Haynes.
I am just happy that I found and fixed the problem.  ;D