xr400 kick start operation

[maxamillion]

I have a complete xr400 bottom end im installing in my 400ex. The kickstart gear meshes up with the idle gear. The idle gear is hidden by the clutch basket when the basket is installed. My question is what drives the clutch basket in order to turn the motor over when you kick this thing?

It seems like there should be a small gear behind the clutch basket that is driven by the idle gear. Im missing something simple here. Can anyone explain the operation of this?

[gcart2]

search the 400ex section.

[maxamillion]

..its not really a 400ex question. anyone got an idea? or maybe tell my how the kick start works on your yfz or 450r. Thanks

[1krazyquadridr]

The XR clutch basket has a gear riveted to the back of it. Look up the microfische and you will see the basket and gear comes as one piece. Since the EX basket holds more plates you will have to find an XR piece and transfer the gear to the Ex basket. Hope this helps.

[maxamillion]

keep in mind the complete bottom end i have is all xr400 parts. the clutch, plates, and everything is all xr400 oem parts. Im just trying to figure out how the kick start assembly operates. The sooner i figure it out the sooner you guys get to see pics of another kick start 400ex :D thnx

maybe ill try to post some pics up of the gears im talking about if that will help.

[1krazyquadridr]

I did the conversion myself, so I know exactly what you are talking about. The kicker gear meshes with the idler gear when kicked, the idler gear meshes with the gear that is riveted to the back of the clutch basket spinning the crankshaft. Make sure that the idler gear bushing sits on the transmission shaft far enough too.

[maxamillion]

clutch basket

[maxamillion]

kicker and idle gear next to main shaft

[maxamillion]

this shows how the basket hides the idle gear. I dont understand how the basket could be driven by the idle gear when the basket pretty much covers up the idle gear when its installed.

[maxamillion]

last one... what you guys think?

[1krazyquadridr]

That isn't a XR clutch basket, it must be an EX basket. A XR clutch basket should have another smaller gear behind the larger one. An XR also uses less plates so it is slightly shorter, you will want to remove the gear from the XR basket and install it on your EX basket It should look like this:
<a href="http://s68.photobucket.com/albums/i6/krazyquadridr/?action=view&current=IMG_8589.jpg" target="_blank"><img src="http://i68.photobucket.com/albums/i6/krazyquadridr/IMG_8589.jpg" border="0" alt="XR400 Clutch Basket"></a>

[maxamillion]

Okay that makes alot more sense now. The basket I got was advertised on Ebay as an xr basket but its obviously not. Now I know what to look for. Thanks for the pic that is a huge help! -Max

[maxamillion]

And if you press on the EX basket to the XR gear, wont you have to buy the aftermarket hinson clutch cover because the basket will stick out further?

[1krazyquadridr]

Yes you will. I've heard of guys grinding out the stock XR clutch cover, but it's a pain. Just another tip though, the complete Hinson unit uses a XR side case cover and they plug the kick start hole with a small plug, and add their slightly wider machined clutch cover. Find a used XR side case and then you just have to buy the Hinson clutch cover. I think there was a Duncan one in the for sale section for fairly cheap.