Clutch Specialists I need your help

[hornetgod13]

With the new clutch kit installed I can not get the clutch to completely disengage. It starts to disengage but no matter how much I adjust the lever or clutch cable I can not get it to completely disengage.

I just installed a new EBC DRC Heavy Duty Clutch Kit. I soaked all the clutch fiber plates in oil and assembled the clutch alternating between a fiber plate and pressure plate. I started and finished with fiber plates and the last one installed was offset in the short slots. Once I got the right crank case installed with the clutch disengager installed properly I rigged the cable/clutch lever as per the maintenance manual.

The clutch not completely disengaging when it's new, is that normal? Do I need to break it in? The only thing I can think is I might have installed the clutch basket washers in the wrong places.

[drew416ex]

I had this problem a few months ago. Do you have any adjustmen left where the cable mounts to the crankcase? My cable is 2 years old so it was stretched a little and I had to do the max adjustments on both there and the lever.

[hornetgod13]

It's a Brand New stock clutch cable and I have the cable adjust 2/3rds the way to the tight side and I even adjusted the clutch lever to no freeplay and it still wont disengage. I guess I can adjust the cable bracket all the way to the tight side (with all threads to the front side of the bracket) but, I think this is odd for a new clutch and cable. Shouldn't it be adjusted more to the loose side with more threads on the back side of the bracket.

[XXXRACER165]

Just to throw it out there. When my dad installed the "Dirt Digger" clutch from Barrnet, he couldn't get it to fully disengage either. It dragged some when you shifted from a dead stop into first and still to this day (it was installed 4 years ago) draggs when it's cold out.

[drew416ex]

Originally posted by hornetgod13
It's a Brand New stock clutch cable and I have the cable adjust 2/3rds the way to the tight side and I even adjusted the clutch lever to no freeplay and it still wont disengage. I guess I can adjust the cable bracket all the way to the tight side (with all threads to the front side of the bracket) but, I think this is odd for a new clutch and cable. Shouldn't it be adjusted more to the loose side with more threads on the back side of the bracket.

Thats what I had to do, but like I said my cable is 2 years old. I wonder if aftermarket plates might be a little thicker than the stock ones. Ive always heard the stocks are thinner. IT doesnt take much to throw everything out of whack.

[hornetgod13]

I will adjust it all they way to the tight side and see how that work. The EBC fiber plates were considerably thicker than stock but, I thought that was because my clutch was worn out.

[shadowwalker]

My stock clutch plates started doing this for some reason. I put a new lever on and no matter how much I adjusted, it never fully disengages. It probably needs new plates and fibers anyways, because it is an 01 and as far as I know has never had them replaced. It was bone stock when we got it a few years ago. And we haven't ever done it:blah:

[hornetgod13]

I adjusted it all the way to the tight side and it will disengage but, the lever is ridiculously tight and I need both hands to pull it and when I let it go It doesn't engage fully. I'm going to tear it apart and check everything. If I don't find anything wrong than I'm going to go back to a stock clutch.

[flauge]

You didnt notice any grooves in the clutch basket, did you?
That might do it...;)

[hornetgod13]

I spent some more time adjusting the cable and lever and rolling the quad in gear with the clutch in and out and I think I got it close to perfect. I'll break it in this weekend if the weather holds up.

[my88r]

my ex the clutch lever is a little more stiff. then other bikes ive had. but i got the 300ex cable. i have it adjusted right to.

[hornetgod13]

Originally posted by my88r
my ex the clutch lever is a little more stiff. then other bikes ive had. but i got the 300ex cable. i have it adjusted right to.

It was a pain in the @$$ to get adjusted properly. I was actually worried that I put something together wrong and I followed the maintenance manual word for word. The heavy duty springs make the lever even tougher to pull. I think I'm going to stick to stock clutch after this one wears out.

[my88r]

Originally posted by hornetgod13
It was a pain in the @$$ to get adjusted properly. I was actually worried that I put something together wrong and I followed the maintenance manual word for word. The heavy duty springs make the lever even tougher to pull. I think I'm going to stick to stock clutch after this one wears out.

when i was at the honda shop last. i pulled the clutch of a 08 ex. it was nice. i try to keep lube on the cable that always helps. its not like my hydraulic clutch on the ktm.lol

[drew416ex]

Ive used ebc plates and springs before and didnt have a problem. It lasted a little over 3 years. Maybe you got a bad batch and they are warped or something.

[flauge]

Id just give it a lil time instead of tearing it back apart.
Back when I put my clutch in, it would creep real bad when I put it in first gear. After a few days it finally stopped. I guess it just needed to be broke in.:ermm:

[hornetgod13]

Too late. I already tore it apart and reassembled it. I found nothing wrong so I will give it some time. It does want to creep when the clutch is pulled in. I have adjusted it as best I can. I hope it gets better.

[exracer416]

what kind of oil did you use when soaking hte clutch plates?? if you used synthetic thats a big no-no, but i believe that will make the clutch slip. some people say to rub the clutch plates on cement to brake them in a little better. or saok them in used motor oil. maybe somebody van elaborate more

[hornetgod13]

I did soak them and used new Valvoline 4 stroke non synthetic motor oil.

[440challenger]

Whats the Number of the kit you bought?

Metals and fibers?

The metals have to go in a certain way. If you take a metal ,and look at it, you see all of the little nubs that fit into the inner hub?
You want to run you finger over the edge of them(like you would to check the sharpness of a knife). There is a sharp side and a rounded side. The sharp side always faces outwards(towards you). Did you offset the last clutch plate?

heres a break down of the spacers
http://216.37.204.206/wps/Honda_OEM/HondaATV.asp?Type=13&A=149&B=12

[hornetgod13]

I finally got it fixed. I went back to stock clutch springs. The clutch is adjustable now and the lever is not ridiculously stiff. I'll never use EBC heavy duty clutch springs again. They were way too stiff.

[flauge]

Originally posted by hornetgod13
I finally got it fixed. I went back to stock clutch springs. The clutch is adjustable now and the lever is not ridiculously stiff. I'll never use EBC heavy duty clutch springs again. They were way too stiff.
Huh? I got EBC's in mine and they're not that much stiffer than stock.:confused:

[morrishemi]

I think there should be a little ball bearing in between the two rods. check if thats there if it isn't the clutch won't work correctly.

rod1, ball bearing, rod2
======0====== thats what it should look like

[hornetgod13]

Originally posted by morrishemi
I think there should be a little ball bearing in between the two rods. check if thats there if it isn't the clutch won't work correctly.

rod1, ball bearing, rod2
======0====== thats what it should look like

You lost me on this one. What rods are you refering to?

[hornetgod13]

Originally posted by flauge
Huh? I got EBC's in mine and they're not that much stiffer than stock.:confused:

There was a Night and Day difference in the stiffness of the clutch springs and lever pull. I'm happy now with the stock springs and EBC plate combination.

[morrishemi]

Originally posted by hornetgod13
You lost me on this one. What rods are you refering to?

Oops never mind I thought the clutch lever was located on the left hand side crankcase cover instead of the right. check this link it has schematics you need to help you locate where washes need to be schematics from bike bandit (http://www.bikebandit.com/houseofmotorcycles/honda-atv-trx400ex-sportrax-400ex-2006/o/m9621)

[flauge]

Originally posted by hornetgod13
There was a Night and Day difference in the stiffness of the clutch springs and lever pull. I'm happy now with the stock springs and EBC plate combination. Maybe the ones in the clutch kits are different than buying them seperate. I just bought the springs. I think they were supposed to be 10% stiffer than stock.

[hornetgod13]

It was an EBC Dirt Racer Heavy Duty Clutch Kit. Those springs had to be 30% stiffer atleast.