Transmission Noise On 400ex

[300EXRD]

HEY ANYBODY ELSE HAVE PROBLEM WITH A NOTCHY CLUNKING NOISE WHNE DOWN SHIFTING INTO 2 OR 1 ?

[ride_a_400]

yeah my buddy's 400ex is having the same problem

[ride_a_400]

yeah my buddy's 400ex is having the same problem

[honda67ex]

yeah my i have a 2001 400ex and i took it apart and it needs 2nd and 3rd gear. they are worn down alot..i think u better get it looked at.

[shortex]

I've got a similiar sound on my 99". I don't notice it when I shift but when I let off the throttle it will occasionaly make the noise, usually around 1st or 2nd gear. It almost sounds like thumping the oil tank with your finger if that makes any sense. Hopefully it isn't the gears but due to its age I would't be suprised.

[300EXRD]

I THINK I'M GOING TO TRY AND LOOK AT IT MY SELF HOW HARD IS IT TO SPLIT THE CASE?

[honda67ex]

well... mine is split right now.. i had someone else do it... its not to easy.. take the head and clyinder off and all that fun stuff then u'll have to lay the motor on its side and pull it apart that way... the tranny will fall into pieces... bushings and bearings and gears and stuff.. just remember how it came apart...other than that.. i dont kno what else to tell ya other than "good luck" ....

[300EXRD]

I talked to a guy at a local shop and he said if you lay it on the clutch side everything should stay put when it is seperated?

[honda67ex]

sounds good to me ... go for it

[SHADETREE101]

well, i just finished putting mine back together. the shops wanted $350.00 just to split it and tell me what was wrong. after a few hours i had it split. it was simple to see what gears were worn and what needed replaced. my second gear shift fork had bent and caused the second gear cog to slip out of gear and chewed up the corresponding gear. i replaced the fork and the bad cog. it took a total of about 8 hours of real careful assembly as this was the first time i split a case, but all went well.

also i do recommed not splitting nothing you haven't dne without the book. i was real careful when i opened it and it still popped and dropped all the gears. the book makes htis a simple process.

good luck

[300EXRD]

I think I found my noise and if that is it I did a lot of work for nothing. I talked to a guy at the local shop and he told me to check the clutch basket to see if it was loose on the main drive gear and sure enough it is. Has anyone else had this problem if so what can you do about it?

[balls2da-wall]

if im correct the clutch basket should be held on with a nut with a locking tab on it...it shouldnt come off if it has that on it!

[300EXRD]

If you remove the clutch assembly then you can tell

[drumaniac3000]

Hey Guys,

My 400 had been making some odd noises once in a while when shifting in 2nd. I was at the dunes a couple weeks ago and went up a hill in 3rd, downshifted to 2nd but 2nd wasnt there. Coasted down the hill and had to limpto camp in 4th. I took it to the dealer and they tore into it and said that the shift fork was bent. Luckily the extended warranty covered it but they wanted 1200bux if it didnt. Does this seem abit high to anyone?? I was shocked when my dad told me. Hopefully it should be done by the end of next week.

Jason

[Aceman]

1200 bucks:eek: Even if they told you it was half of that, it would still be outrageous. You could go through servicehonda.com and buy a full gasket set and shift fork for under 150 dollars. No way in hell I would pay 1200 to have it fixed. For the other 1050 bucks I'd figure out how to do it myself.

[drumaniac3000]

Thats what I thought aceman. They said something like 280 to split the cases and I figured that the parts would be something like 120 for a total of maybe 400. I'm glad the warranty covered it.

Jason