The XR400 Thread - Page 369

mark1150 · 02-17-2013, 02:19 AM

Quote:

Originally Posted by DrLewall

ALSO...before you take the clutch apart, check to make sure that who ever had the bike before you didnt install the clutch plates wrong (yes it does happen and it happened to me)..the outermost clutch plate has to be in it own groove by its self in the clutch basket..it's so easy to line all the plates up in the same notch/groove..the last plate has to be by it's self in its own notch.

good luck

Those pictures (above) speak a thousand words, when I read the original post I couldn't figure out where you were coming from.
Thanks for taking the time to make things clear.

MartiniUp · 02-17-2013, 11:05 AM

The clutch thing does make a difference, thanks for the pics Doc. I wonder why Honda did that.

DrLewall · 02-17-2013, 12:47 PM

Quote:

Originally Posted by RideFreak

The plates in the incorrect orientation shouldn't keep the clutch from working, it's not optimal though.

this is true..although who ever had this motor before me, installed the plates wrong, the clutch did work..I put abt 8,000 miles on that motor with the clutch like that, BUT, every now and then, the clutch would chatter and grab, not all the time mind you, maybe once or twice a month, if that..it worked okay and I made do. It was hard to find neutral tho. I always had to fight with it to get into neutral with the motor running in idle. Was easier to stop the motor and find neutral.

So one day I fired it up. The clutch chattered and grabbed as I let the lever out and it was almost to the point of launching me as I let the lever out some, it was in severe grab mode and didn't feel right.

So I wanted to see what was going on in there and I removed the cover, and there it was, it jumped out at me right away. All this time I had been running it with the plates (the last plate) installed wrong. Super easy fix, and I did fix it.

Now I can find neutral in idle, SUPER EASY!!!

The chatter and grab'n are gone

The XR400 seems like it even shifts easier now.

The lesson I learned here, new to me motors, need to have the clutch looked at just incase they are not put together right, at a minimum.

After checking your clutch and you still have shifting issues, then I would suspect some other mechanical snafu.

tbarstow · 02-17-2013, 03:05 PM

Quote:

Originally Posted by MartiniUp

The clutch thing does make a difference, thanks for the pics Doc. I wonder why Honda did that.

Yes it does. I fixed mine last night, then spent all day riding out here in the desert. Worlds of difference.

Now if I could just get some decent wide ratio gearing......

Clem Kevin · 02-17-2013, 03:44 PM

Hmmm, you guys have me wondering. I've had my XR400 for six years and still have a bitch of a time getting it into neutral, never opened the clutch once.

aaron2a · 02-17-2013, 04:12 PM

I'm checking mine tomorrow... I'm putting a new tank on and cleaning my carb also... Tank is cracked and carb keeps sticking.

Ed@Ford · 02-17-2013, 05:00 PM

Quote:

Originally Posted by tbarstow

Now if I could just get some decent wide ratio gearing......

My wish since 1997!!

RideFreak · 02-17-2013, 06:42 PM

If the clutch plates are oriented incorrectly, it's not going to be as good as it could be if installed correctly but it won't cause the transmission to jump down a gear or jump out of gear. DrLewall's pic above showing the incorrect placement is how clutches have been made for years, all the fiber tabs are in a line, many are still that way. If Aaron's description is correct, the 5th gear slippage could easily be the problem DrLewall pointed out but the jumping up or down a gear unfortunately is another problem. A properly working modern dirtbike transmission (which includes the XR4) doesn't require the clutch at all to shift correctly while moving.

DrLewall · 02-17-2013, 07:12 PM

Quote:

Originally Posted by tbarstow

Yes it does. I fixed mine last night, then spent all day riding out here in the desert. Worlds of difference.

Now if I could just get some decent wide ratio gearing......

so did you find your plates installed wrong?

Quote:

Originally Posted by Clem Kevin

Hmmm, you guys have me wondering. I've had my XR400 for six years and still have a bitch of a time getting it into neutral, never opened the clutch once.

Quote:

Originally Posted by aaron2a

I'm checking mine tomorrow...

would be curious to know what you guys find also..keep us posted!

tbarstow · 02-17-2013, 10:58 PM

Quote:

Originally Posted by DrLewall

so did you find your plates installed wrong?

Yep. Good thing I only have 2 rides on the clutch since I replaced the plates and didn't put the last one in the correct orientation.

Clem Kevin · 02-18-2013, 12:13 AM

Quote:

Originally Posted by DrLewall

would be curious to know what you guys find also..keep us posted!

It'll be a few weeks before I do, currently tearing down a yz250f to use for supermoto.

aaron2a · 02-18-2013, 04:42 PM

Not the problem. They are installed correctly.

DrLewall · 02-18-2013, 05:11 PM

Quote:

Originally Posted by aaron2a

Not the problem. They are installed correctly.

bummer!

then most likely you have a mechanical gremlin pesterin you..good luck

but at least your clutch is assembled correctly..and most likely, your clutch plates would mic out okay too..they do wear but it takes along time for them to do so, years in fact!

aaron2a · 02-18-2013, 05:24 PM

We'll it is 15 years old... No clutch work that I know of... Might just need new clutch plates?

cirell · 02-19-2013, 02:56 AM

I know its already on here somewhere but can some one tell me if the stock stator will run a 55watt HID light? Or would I need to upgrade to a bigger stator.
Thanks

02-17-2013, 06:42 PM	#5528
RideFreak Torque Junkie Joined: Apr 2009 Location: County Lockup Oddometer: 3,553	If the clutch plates are oriented incorrectly, it's not going to be as good as it could be if installed correctly but it won't cause the transmission to jump down a gear or jump out of gear. DrLewall's pic above showing the incorrect placement is how clutches have been made for years, all the fiber tabs are in a line, many are still that way. If Aaron's description is correct, the 5th gear slippage could easily be the problem DrLewall pointed out but the jumping up or down a gear unfortunately is another problem. A properly working modern dirtbike transmission (which includes the XR4) doesn't require the clutch at all to shift correctly while moving. __________________ *Chris* VIDEOS

02-19-2013, 02:56 AM	#5535
cirell Adventurer Joined: May 2010 Location: Sunshine Coast Oddometer: 60	hid light I know its already on here somewhere but can some one tell me if the stock stator will run a 55watt HID light? Or would I need to upgrade to a bigger stator. Thanks

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02-17-2013, 11:05 AM	#5522
MartiniUp Studly Adventurer Joined: Jul 2010 Location: TX Oddometer: 810	The clutch thing does make a difference, thanks for the pics Doc. I wonder why Honda did that.

02-17-2013, 03:44 PM	#5525
Clem Kevin Nude With Boots Joined: Aug 2007 Location: Santa Cruz, CA Oddometer: 495	Hmmm, you guys have me wondering. I've had my XR400 for six years and still have a bitch of a time getting it into neutral, never opened the clutch once.

02-17-2013, 04:12 PM	#5526
aaron2a supermoto hooligan Joined: Feb 2013 Location: canton, ms Oddometer: 38	I'm checking mine tomorrow... I'm putting a new tank on and cleaning my carb also... Tank is cracked and carb keeps sticking.

02-18-2013, 04:42 PM	#5532
aaron2a supermoto hooligan Joined: Feb 2013 Location: canton, ms Oddometer: 38	Not the problem. They are installed correctly.

02-18-2013, 05:24 PM	#5534
aaron2a supermoto hooligan Joined: Feb 2013 Location: canton, ms Oddometer: 38	We'll it is 15 years old... No clutch work that I know of... Might just need new clutch plates?