Clutch problem???

I have a 2001 400ex. Ever since I got it, the clutch has been pretty hard to squeeze. It's stock. My brother has xr400 and it is much easier to pull back on (you know, same motor and all.) Until today, I have just written it off as, "that's just the way EX's are."

Today, I went to the Honda dealership and jumped on a new 400ex, and that clutch was like butter. So I ran into the back and I talked with a guy in the service department and he wasn't much help. He said that he would have to look at it, and that I would need to bring it in and it would take a week to get to it. I am like NO WAY am I going to leave my baby up there for a week. So I tried to compromise and told him that I could bring it up there in a week. He said, "Sorry, we don't do appointments."

Anyway, I am resorting to you all for any tips.

To give you some insight.....It's hard to pull back, and it let's out with force too. It's like there is a spring that needs to be loosened or adjusted. I don't know what it is, and I don't want to screw anything up.


I have taken off the clutch cable to make sure that it wasn't just snagging somewhere (it wasn't) and I also greased it up. It didn't help a lick.


Is there a way to fix this? Or is it just my 400ex's personality!?!?!

Thanks for your help.

[Deathbringer]

Man thats tuff... but I would go for maybe you have pulled the tension on the cable way to tight. You might try releasing as much tension of the cable as you can, I would go all the way out, then work your way in till the clutch works.. Remember there are two adjustments, one is up on the lever and the other is where the cable attaches down by the motor. Also while you are messing with it check the the lever also, it may have gunk in it which is making harder to pull then it should be.
Oh also try pulling it by hand down by the motor and see if that pull in and out easy.. Just some ideas to try hope they help... if not...and you don't feel comfortable pulling your bike apart, I think you are stuck taking it to the dealer.

I have loosened the clutch cable and done everything that I know to do with it. I have even greased the cable and made sure that it wasn't getting hung up somewhere.

I think the problem is with the little rotating lever down by the motor. It's impossible to move without the clutch/pulley system. I don't know if it's that rotating lever or something inside. I haven't opened up the motor to see what could be the problem because..

#1- I don't know what I am looking for.

#2- I don't know if there is something that can even be done if I find what I am looking for.

I hope I am clarifying this problem.

By the way...I have no problem taking anything apart on my bike to keep it out of the shop. It's just putting it back together! ;-)

Thank you so much for your help.

[twisted threads]

Todd my buddy just had the same problem with his cable so he got a new one and now it works great. The old cable was frayed and it was gummed up with dirt and stuff in the cable.

[Colin400EX]

I would open up the clutch and look at it. Invest in a service manual for your bike (I got the Clymer and it seems to be pretty detailed about the clutch) and keep track of any parts you take off (including bolt ordering and such so when you put it back together, you put everthing back in the exact same spot.)

A friend of mine had a problem with his clutch on his mx bike, and part of the problem was the clutch basket had pieces broken off, but it sounds more like something isn't put on right. If the clutch is hard to pull even by using a channel-lock or something, instead of the cable, then it wouldn't matter if the cable was frayed.

Edit:
http://www.servicehonda.com/HARD%20PARTS/atv/trx400ex/clutch.jpg

Clutches are actually simple components (atleast the ones for kx125s are). You have a basket(3) connected to a gear(11) that connects to the crank. In it, you have disks(6) that have notches on the outside that fit into slots in the basket. Between those you have disks(7) that have notches on the inside that connect to the tranny. As you pull the clutch in, it pushes the pressure plate(8) holding the second set of disks against some springs between it and the clutch center(5). This lets up the pressure forcing the 2 sets of disks together, causing the power from the engine to no longer go from the drive shaft to the tranny. You can't see it from the picture, but part 5 goes through part 8, and the springs go around the "columns" and then screwed down. Thus, letting go of the clutch lets the springs push the disks together.. Compared to the rest of the engine, the clutch is probably fairly simple..

Edit: I may have which piece gets pushed when you pull on the clutch swapped, but I don't have the manual in front of me to double check.

[Colin400EX]

One other thing.. What's the angle from where your clutch lever (part 7 on the clutch coverdiagram: diagram (http://www.servicehonda.com/HARD%20PARTS/atv/trx400ex/right_crankcase_cover.jpg)) from the clutch cover when the cable is removed? Does it point towards the front of the bike?

Edit: btw, you won't be able to move it with your hands, but if you use a pair of channel lock pliers you should be able to rotate it without too much effort.

Thank all of you for responding. I appreciate it.

I will let all of you know what is up with my clutch as soon as I diagnose the problem, hopefully this weekend.

I love this site!!!:D

[RytM1]

Did you buy your 400 new or used. If you bought it used, maybe the previous owner put some heavy duty clutch springs in.

My 400ex has always ahd a light clutch pull, never a problem, but my dad's was a different story, it was 4x harder. What the problem could be like his was when the dealer put it together they didn't route the cable correctly and the heat from the header melted the sleeve. Probably not a common thing but just in case check the cable around the header and make sure it isn't too close.

[honda400zx]

wait dont rip it apart!
buy a cable luber there like 4 bucks and itll solve ur problemmine did the exact same thing and rico told me to buy one do it u wont regret it!

Thanks ya'll. But here's the update:

It was my birthday the other day and my bro ordered me some new clutch plates.

I am not sure if they are going to solve the problem, but it will give me an excuse to get into the clutch area and look around.

He bought me some EBC clutch plates.

I am suppose to get them this week and I plan on installing them as soon as I get them.

I am not thinking that they will solve the hard pull, but it will give me a chance to look in there. I have a funny feeling that one of the main springs may be in there crooked or something.

I don't know, it's just a guess. I will keep everyone updated. But please keep responding because I am open to any possibility.

By the way, I have lubed her up. It didn't work.

Hey i just picked up a new 400 ex. The clutch had a nice light pull. Then on a recent trip, from one shift to the next the pull went from light to hard. I took it in to the dealer they checked it out & said there was nothing wrong. Not being happy with that i started checking around. I found 9 400ex bikes & only one has a hard pull like mine. I AM TAKING IT BACK TO DEALER TO HAVE IT FIXED. If you work out your problem let me know.