Clutch blew up!!!

[20Honda400ex00]

http://i393.photobucket.com/albums/pp16/Rinell88/Untitled-4-7.jpg

http://i393.photobucket.com/albums/pp16/Rinell88/Untitled-1-12.jpg

http://i393.photobucket.com/albums/pp16/Rinell88/Untitled-2-13.jpg

Clutch Pressure plate.

http://i393.photobucket.com/albums/pp16/Rinell88/Untitled-10-4.jpg

Clutch Springs.

http://i393.photobucket.com/albums/pp16/Rinell88/Untitled-6-4.jpg

http://i393.photobucket.com/albums/pp16/Rinell88/Untitled-13-4.jpg

Dont know why or how it happen, Had the clutch apart a couple weeks ago to replace the lifter pin. When I put everything back together I torque them down to spec.

Now heres what im worried about, Their is only 4 springs and a little left of the the 5th spring. Where did most of the the 5th spring go? Not sure what the other side looks like yet. I can see their is metal shavings inside the case and was wondering what would be the best way to get most of them out without damaging the quad?

Also would the 450r Clutch basket fit in the 400?

Think i'm going to replace everything with hinson components. What are your thought on hinson worth the money or not?

[20Honda400ex00]

I emailed hinson to see what all they had for the 400ex and they only make the basket.

What would be another good company to go with that has the pressure plate and in hub?

[togup]

that sucks, the missing spring fragment is most likeky laying under the crank, there is a large triangular hole flush with the bottom of the cases that is directly under the clutch that goes into the mid case , dig in there with a telescopic magnet and see if you pick it up although I recomend a complete tear down unless you can figure out some way to irrigate the case to flush all the metal particles dont forget to pull the oil pump intake screen and clean it. Also the clutch engaging lever looks dammaged at the bottom pivot

[smorris1]

how does that happen? hahaha

[20Honda400ex00]

Togup, I think im going to flush it would with kerosene fist before I go any farther in tear down.

The oil pump Intake screen, where is that located?

Yes the clutch lifter shaft is damaged.

[20Honda400ex00]

Originally posted by smorris1
how does that happen? hahaha

Because its my luck something like this would only happen to me.

[togup]

Originally posted by 20Honda400ex00
Togup, I think im going to flush it would with kerosene fist before I go any farther in tear down.

The oil pump Intake screen, where is that located?

Yes the clutch lifter shaft is damaged.

look at your 3rd picture,bottom of the case ,between the oil pump and clutch there is a single bolt think its a 10mm, take it out and pull the flange behind the bolt then start your flushing.

[Pabst_Powered]

:ermm: wow this must be contagious, this happend to mine about 2 weeks ago, I took a tele magnet and put it anywhere and everywhere I could for debris, sprayed everything inside with parts cleaner, bought a magnetic motor oil plug, 2 gallons of oil, 4 oil filters, and a complete used clutch off the bay, put it all back together and ran it for a few, changed the oil 4 times one after another and everything seems fine, hope this helps

[NacsMXer]

Originally posted by 20Honda400ex00
I emailed hinson to see what all they had for the 400ex and they only make the basket.

What would be another good company to go with that has the pressure plate and in hub?

Hinson makes the basket, pressure plate, and inner hub but for the XR400. It's the same motor i'm sure you already know. Unless they stopped making the pressure plate and inner hub for some reason which would suck. I would call them back about that. I have the complete setup and it about as stout a clutch setup as you can get. Seeing all these clutch catastrophes in the last couple of weeks makes me feel even better I spent the extra for the Hinson components :eek2:

I wonder what caused these two failures because you really don't hear about stuff like this often..

[gtt416ex]

Originally posted by NacsMXer
I wonder what caused these two failures because you really don't hear about stuff like this often..

I know :eek2: I've never seen this happen before. I've replaced my clutch three times and haven't had any problems.

[Foxhound013]

Yeah these last two explosive clutches threads have me a little worried, we just bought an EBC clutch kit with heavy duty springs and we're puttin it in soon lol, not trying to hijack the thread but any opinions on whether i should use the HD springs or stockers?

[sc400ex_rider]

Originally posted by 20Honda400ex00
http://i393.photobucket.com/albums/pp16/Rinell88/Untitled-4-7.jpg

http://i393.photobucket.com/albums/pp16/Rinell88/Untitled-1-12.jpg

http://i393.photobucket.com/albums/pp16/Rinell88/Untitled-2-13.jpg

Clutch Pressure plate.

http://i393.photobucket.com/albums/pp16/Rinell88/Untitled-10-4.jpg

Clutch Springs.

http://i393.photobucket.com/albums/pp16/Rinell88/Untitled-6-4.jpg

http://i393.photobucket.com/albums/pp16/Rinell88/Untitled-13-4.jpg

Dont know why or how it happen, Had the clutch apart a couple weeks ago to replace the lifter pin. When I put everything back together I torque them down to spec.

Now heres what im worried about, Their is only 4 springs and a little left of the the 5th spring. Where did most of the the 5th spring go? Not sure what the other side looks like yet. I can see their is metal shavings inside the case and was wondering what would be the best way to get most of them out without damaging the quad?

Also would the 450r Clutch basket fit in the 400?

Think i'm going to replace everything with hinson components. What are your thought on hinson worth the money or not?

What are your mods? what year you got? how many hours on it? by your name im guessing a 2000.? i think the one from 2 weeks ago was a 1999 with hd springs.

[20Honda400ex00]

Originally posted by sc400ex_rider
What are your mods? what year you got? how many hours on it? by your name im guessing a 2000.? i think the one from 2 weeks ago was a 1999 with hd springs.

I have not done any mods to it yet. When I bought it is had a big gun full exhaust done and that was it. Yes its a 2000, yes I understand that things do break over time, and with this being 10yrs old it dose not surprise me. Just was upset when it happened because I was ridding at the track.

Sorry I haven't responded to every one post. Been real busy at work 12 hr shift and not getting home till 4am takes its tole. Ill try to post back maybe sat after my 16 hr shift, if I don't it will be on Sunday.

Thanks for all the info so far.

[honda400ex2003]

Originally posted by Foxhound013
Yeah these last two explosive clutches threads have me a little worried, we just bought an EBC clutch kit with heavy duty springs and we're puttin it in soon lol, not trying to hijack the thread but any opinions on whether i should use the HD springs or stockers?

my hd setup has been good for a couple of years now. This is really the first 2 i have heard of having this same issue. weird, and interesting? steve

[sc400ex_rider]

this looks like an area that needs to be closely inspected. i got an 02 with low hrs but the motor is built. im just wondering what went first. the pressure plate stress cracking/breaking on 2 then ripping out the 3 hub bosses or what?

[CJM]

Im wondering if its improper torquing, failure of the parts for some reason or the use of HD springs?

[20Honda400ex00]

Originally posted by NacsMXer
Hinson makes the basket, pressure plate, and inner hub but for the XR400. It's the same motor i'm sure you already know. Unless they stopped making the pressure plate and inner hub for some reason which would suck. I would call them back about that. I have the complete setup and it about as stout a clutch setup as you can get. Seeing all these clutch catastrophes in the last couple of weeks makes me feel even better I spent the extra for the Hinson components :eek2:

I wonder what caused these two failures because you really don't hear about stuff like this often..

I did not know about the XR400. I checked on Hinsons web site and they make everything but the pressure plate for the XR400R.

Where did you order the clutch from and how much did you pay for it? Ive looked on ebay and on CL for the XR400 clutches and theirs not that many.

[20Honda400ex00]

Originally posted by CJM
Im wondering if its improper torquing, failure of the parts for some reason or the use of HD springs?

When I had it apart to put the lifter pin in I torqued the springs down to 9 Ft-lbs, In a star pattern.

I think the springs in mine were stock.

[CJM]

I honestly forgot to even torque mine down, I just tightened mine down snug.

[honda400ex2003]

i think i did the same. I tried to torque them correct and broke one of the bolts off and had to fish it out of there. at least they screw in really easy and back out just as simple with no head on them. lol steve

[NacsMXer]

Originally posted by 20Honda400ex00
I did not know about the XR400. I checked on Hinsons web site and they make everything but the pressure plate for the XR400R.

Where did you order the clutch from and how much did you pay for it? Ive looked on ebay and on CL for the XR400 clutches and theirs not that many.

I had the Hinson stuff put in when my motor was at GT Thunder being built. I can't recall where I bought them at the time as it was several years ago. It might have been Ebay.

I found numerous Hinson pressure plates from Hinson for the XR400 with a quick Google search. There's one on Ebay right now for $156.99. Otherwise they retail in the $190 range. The Hinson inner hub is like $270. The Hinson basket is anywhere from $210-220. The stuff isn't cheap but it's about the best you can get, and definitely won't explode like the stock cast aluminum parts as we can see here.

If you use the Hinson components together, you can add 1 more fiber plate and 1 more steel turning your clutch into a 8 plate clutch. You use thinner Honda 250R clutch fibers/steels to achieve this. What you get is a lot better holding power, and longer clutch life having extra plates over stock. The Hinson stuff is also a ton more resistant to wear, so you don't have to worry about issues like grooves in the clutch basket and stuff like that anymore.

Here's a pic of the full setup with the 250R plates. If you count you can see there's one extra fiber/steel in there.

http://img704.imageshack.us/img704/5148/dsc0115zr.jpg (http://img704.imageshack.us/i/dsc0115zr.jpg/)
http://img837.imageshack.us/img837/3082/dsc0119t.jpg (http://img837.imageshack.us/i/dsc0119t.jpg/)