clutch brake in

[gt400ex]

im just about done replacing my clutch and was wondering if there is a right way to brake it in? plus is the clutch cable suppose to be routed in front or behind the oil cooler? i forgot how it goes after pulling it out of the way. and thanks for any help.

[BEAVER.989]

I'm not sure about break in, but the cable goes behind the oil cooer. I noticed how close it is to the header just yesterday when I installed a new clutch perch and had to adjust it.

[yellow02400ex]

I have never done anything but ride It after I put a new clutch in. I wouldn't pop or dump the clutch for a wile after putting it in just to be safe.

[Honda#4]

I just got done putting mine in and I just rode it around normally just so everything gets properly broke in kinda like breaking in a motor.

[honda400ex2003]

that is what i did. i just rode it for a while to break it all in. it will move quite a bit actually. steve

[smokindw]

now how hard is it to put in a new clutch kit and what one is the best? i need a new clutch and my 440 is runnung super hot and was wondering which is the very best aftermarket clutch kit out there??

[honda400ex2003]

it is not too hard to do. you just take the side cover off and change the plates by taking the pressure plate off. i use a tusk set that works well. If you are looking for the best, hinson is the best and i would get a basket too. steve

[rob_990]

its really easy if you get a clutch holder tool

[honda400ex2003]

much easier i would get one. steve

[smokindw]

is this the tool ur talking bout??
http://fstg.motosport.com/motographics/images%5Cproducts%5Chardparts%5Ctools%5CMotionPro_ ClutchTool.jpg

[honda400ex2003]

link does not work for me at least. but i am sure that is the one. if it looks like a spider or a flywheel puller sort of tool that is the one. it will make it so it does not spin around on you but you only need that if you are going to get a basket too. to change the plates only you dont need it. steve

[smokindw]

whats the diff between the steel 6 plate kit and the fiber 7 plate kit except the steel is 50 and the fiber is 90bucks??
http://www.motosport.com/atv/product/HINSON-CLUTCH-STEEL-PLATE-KIT-6-PACK/?catalogId=114549
http://www.motosport.com/atv/product/HINSON-CLUTCH-FIBER-PLATES-7-PACK/?catalogId=114547
and this kit is alot more $$ why is this
http://www.motosport.com/atv/product/BARNETT-CLUTCH-KIT/?prodId=28763&

[NacsMXer]

Originally posted by smokindw
now how hard is it to put in a new clutch kit and what one is the best? i need a new clutch and my 440 is runnung super hot and was wondering which is the very best aftermarket clutch kit out there??

Full Hinson 8 plate clutch with OEM Honda fibers/steels is pretty much as good as it gets. Mine has performed excellent, last time I did my clutch there was like no visible wear on any of the Hinson components. Quite expensive though to buy all at once.

If you want something similar, but a good bit cheaper, look into the Sparks Racing or GT Thunder 8 plate clutch kits for the 400EX ;)

[NacsMXer]

Originally posted by smokindw
whats the diff between the steel 6 plate kit and the fiber 7 plate kit except the steel is 50 and the fiber is 90bucks??
http://www.motosport.com/atv/product/HINSON-CLUTCH-STEEL-PLATE-KIT-6-PACK/?catalogId=114549
http://www.motosport.com/atv/product/HINSON-CLUTCH-FIBER-PLATES-7-PACK/?catalogId=114547
and this kit is alot more $$ why is this
http://www.motosport.com/atv/product/BARNETT-CLUTCH-KIT/?prodId=28763&

It is a different price because they are 2 different items. But every clutch is made up of alternating fiber and steel plates. You can't have a clutch pack without fibers and steels.

Stock, the 400EX has 7 fiber plates and 6 steel plates. When you upgrade to an "8 plate clutch", you will have 8 fiber plates and 7 steel plates. The extra plates in addition to heavy duty clutch springs will give your clutch much more holding power over stock. This translates into more power to the ground, and less heat generated from slippage.

I wouldn't waste your money on the Barnett kit. It is decent, but you would be much wiser to upgrade to an 8 plate clutch kit. Check it out: http://www.alwaysopenmall.com/layouts/02/unsecure/item.asp?SiteID=223&DepartmentID=85&CategoryID=949&GroupID=7034&ItemID=36574&StartNum=1&Sort=&ShowPics=0&ListByCode=1&Brand=&GenderAgeGroupID=0&MaxPrice=&SearchString=&ItemCode=&IsOnlyOnSale=0&FromHomePage=0&FromFamily=0&ProductFamilyID=0&RelatedItemID=0

[honda400ex2003]

you need the whole kit. the 2 deperate ones are both needed since there are fiber plates and steel plates in the clutch. they go every other one. that is why there are seven of one and 6 of the other. one goes outermost and innermost with the others inbetween. steve

[smokindw]

ah if its good then the money im willing 2 spend!! where can i find these products, i prefer 2 buy all in 1 place??

[honda400ex2003]

Get the one from the lnk that nacs put up. that is the best one you will find. you can get the basket also and be really set up. steve

[smokindw]

now would this be a good basket and will the basket make the install any harder?? I have never even seen the inside of the clutch!! Im pretty good though with modding my 440 but like i said can i do this i dont wana take it 2 my stealership they are money hungry sobs!!!
http://www.alwaysopenmall.com/layouts/02/unsecure/item.asp?SiteID=223&DepartmentID=85&CategoryID=949&GroupID=7034&ItemID=36966&StartNum=1&Sort=&ShowPics=0&ListByCode=1&Brand=&GenderAgeGroupID=0&MaxPrice=&SearchString=&ItemCode=&IsOnlyOnSale=0&FromHomePage=0&FromFamily=0&ProductFamilyID=0&RelatedItemID=0

[honda400ex2003]

the basket is just one more nut back behind the plates. steve

[smokindw]

so basically im takin the plates off anyways so i should just replace the basket while im in there?

[smokindw]

also i know that i will need the clutch tool but wont i need a gasket 2 and i also wanted 2 say u guys are freakin great!! Ive learned more on here the last couple months then i thought that i ever would!!!
THANKS GUYS

[honda400ex2003]

you will probably want to get a side case gasket also and if your basket is grooved or if you want to get a new one go for it. it ccant hurt anything to get a new one and hinson ones are by far the best. they are quite a bit of money though. if you decide not to do the basket you should not need the tool. no prob on the help any time. steve

[honda400ex2003]

so if you want the whole thing and have a few hundy for it,

basket
http://www.alwaysopenmall.com/layou...RelatedItemID=0

plates
http://www.alwaysopenmall.com/layou...RelatedItemID=0

gasket
http://www.magicracing.com/Clutch-Cover-Gasket--TRX400EX_p_279.html
(something along the lines, i would get an oem one or a cometic if you can find one)

tool
http://www.magicracing.com/Motion-Pro-Clutch-Holding-Tool_p_5072.html

that should be about it. that tool may be different than the one you had but it should work. you can get what ever one you like. good luck, steve

[smokindw]

wow thanks man!! i was reading bout the cometic clutch gasket on motosport n couple of the guys who bought them said that the were garbage and wouldn't fit, i think that im gona go with the oem ones but thanks alot for the links!!!!

[honda400ex2003]

hey no prob you cant go wrong with the oem one. my cometic one is still good after taking my cover off once since i first installed it but mine was in the kit with the full set from my rebuild. good luck and let me know what you end up doing. steve

[gt400ex]

Originally posted by smokindw
now how hard is it to put in a new clutch kit and what one is the best? i need a new clutch and my 440 is runnung super hot and was wondering which is the very best aftermarket clutch kit out there??

thats good to hear because i got the tusk with the heavy springs. do the heavy springs make much difference in the clutch operation?

[NacsMXer]

Originally posted by gt400ex
thats good to hear because i got the tusk with the heavy springs. do the heavy springs make much difference in the clutch operation?

Yes the heavy duty springs will increase the holding power.

[honda400ex2003]

mine works good with the hd springs. steve