quick change clutch cover??????????

[hiway6969]

i know ive seen quick change covers before, but know i cant find one any where! does any one know if they are still being made, or where i can get one? i already looked at the duncan site, ive got a 05 so i know my cover is different than the first gen 400ex. ah i can only fantasize about the luxury of changing my clutch with out the head ache of that huge oem cover and the hard to reach bottom section where the gasket always seems to turn into a cement lol

[Chukkinsod]

Hinson is the only one that I know of, but I think they stopped making them......put a post in the wanted sction

[PaRedneckRiders]

you pretty much need to buy an XR400 cover and fill in the whole for the kick starter. Thats pretty much the the 400ex cover is but they changed it from the quick change to the way it is now.

iirc the clutch side cover of the XR one is a little shallower though so you have to use the hinson clutch basket. Not sure if that was if you changed the cover or not you would have to check.

Id like to have a quick change to, would make it alot nicer to work on clutches, ive seen i done before and im sure everyone used the XR400 side case but i dont remember how or if they had to modify the clutch basket.

[togup]

I have an xr cover with a Duncan cover stock clutch had to modify clutch lever on the cover and the cable mount

[togup]

Ive also seen Boysen covers for the xr for about 80 bucks at motor sport .com the funny thing is after you install it you never need it but its worth it, oh yea bought the case at service honda

[CJM]

What did you have to modify on case lever for clutch cover?

Couldnt you just use a XR400 cable?

[togup]

I cut the lever in half mocked it up then added 1/2 then tig welded it to make it look nice then I cut the hole on the clutch cabe stay closest to the cover off then redrilled it basicly making it shorter but when you do the mod that is self explanitory ill post some pics if you want more detail . its possible that an xr clutch arm may need no modification, a ex arm is 2" my modified arm is 2 1/2"

[togup]

no need for any cable modification

[CJM]

Interesting, I would indeed like some pics if possible.

I do wonder if the XR lever would work better. The part numbers are different for a 400ex and an xr400.

[togup]

swing by the honda dealer and measure an xr lever and compare with my measurements

[togup]

pic of modified cable stay

[togup]

pic of plugged kickstart

[togup]

the red clutch arm is the factory ex the black one is the extended one

[togup]

without cover

[togup]

another pic of the clutch arm

[CJM]

thanks for the pics I appreciate it. I think im gonna do this mod as it would be really nice to be able to swap the clutch quickly.

[hiway6969]

to bad it wont work for 05+........................................:(

[togup]

oh yea almost forgot youll need more bolts to for the removable cover so I bought a stainless bolt kit for the XR 400 off of ebay and replaced all the bolts on my motor ,I think it really cleans up the motor nicely

[CJM]

Thanks for the info. This is one of those mods Im gonna do sooner or later just because its fun and functional.

[CJM]

sorry to revive this, but togup did you need a aftermarket basket or anything or does it fit fine with stock parts?

[togup]

no I have all stock clutch parts , never used any aftermarket clutch parts so If you do I really cant help there but will be glad to help if you need any measurements. Mine just bolted on pretty easy.

[CJM]

Just was checking, couldnt find any definitive info if you needed a different basket or whatever.

Thanks again :)

[Nac's22]

Togup- What did you use for the plug for the kick start hole?

[atvextremerider]

Originally posted by togup
I have an xr cover with a Duncan cover stock clutch had to modify clutch lever on the cover and the cable mount
hey does duncan racing still make though's?

[bkb88]

I couldn't help but noticing, couldn't I just go to a place that manufactures bearings and seals to see if I can get a rubber cap like the ones that come with the 450er and yfz450? I checked out the 450er cap and it is 2mm off. The 450er seal measures at 20X28X5 for the optional kick start and the xr400 seal measures in at 20X30X7. I'm sure that a 30mm cap can be made or probably already exists. This is the route I will be taking when I put mine on. I found the whole assembly for a 96' xr400 for $55 including the xr400 clutch cable arm!

[CJM]

bump
this thread explains a 1996 XR clutch lever arm is longer than the EX and will fit with no issues.

http://www.exriders.com/vbb/showthread.php?s=&postid=4109035#post4109035

keep in mind though fellas there is a wire mesh screen held in by one bolt directly underneath the clutch.That should be cleaned after everytime any motor work is done at the time of break in oil change(my recommendation) and honda recommends doing it anytime the clutch side case cover is off the machine.oil has to pass through that before its drawn through the pump. rock those quick changes but dont set it and forget it.they can get pretty ugly if not cleaned especially on the older machines.

[bkb88]

Good point, I have cleaned mine out once in the year I have owned it and looked at it again today while putting in my new clutch.

I wasn't very surprised to see that more crud had made its way to the screen in the 8 or so months since I cleaned it last. This should definitely be a mandatory yearly maintenance task to keep the screen free of debris and also check the screen at the oil tank.

[hondaREX]

Togo. I have the XR400 cover with the same Duncan quick cover. The Duncan came with a lever but im unsure right now if it is the same as the EX. I also have an XR 8 plate hinson basket, hub, and pressure plate. Im going to take some pics and post them so i can get some info before i do the swap. I havent been into the EX yet and dont know what differences there are. I should just do it and find out. Ill get some pics up soon.

[Pappy]

I don't recall having to buy anything regarding the lever.

I do know this, be careful with that new case/cover. It is VERY weak in the one area(cant miss it, thinist part between the replacement cover and the case). I cracked mine just handling it. Thought it was a fluke until I broke #2!

[hondaREX]

Pappy. You just made me go check. My case/cover looks perfect. I will be storing it with more care now. Also, noticed the cover is a Hinson not a Duncan and that the lever is the same length as the stock EX lever. Ill have to take a shot at extending the stock one.

[Pappy]

No problem, one drop off the work bench and its off to get welded :ermm:

[bkb88]

It seems that a stock xr400 clutch cover will not work with the stock 400ex lifter/clutch basket assembly. The clearance was fine for the clutch basket but the clutch lifter was too long for the shallow xr400 clutch cover and would not dis-engage the clutch.

From what I have seen, the aftermarket clutch covers for the xr400 stick out farther than the stock xr400 cover. I have also noticed that the stock cover's clutch arm location is angled to the front of the bike about 1/2" forward. After speaking with the custom cable department at Motion Pro, I found out that the xr400 clutch cable inner wire was an inch shorter than the 400ex. The outer sheath was only a half inch longer on the xr400 as well. It looks like this must be used in order for the stock OEM cover to be used.

Just adding to the information on the xr400 clutch cover mod. :)