Honda 400ex Clutch not disengaging? Help!

[HndaRcing8]

Just picked up a quad and I knew it had this problem just trying to figure it out. Replaced the clutch cable, bit still disengaging. He said that it started over the winter and then jusy gave up and.don't have the time.

Any help would help.

[HndaRcing8]

Not disengaged I mean, also its an 2004 Honda!

[HndaRcing8]

http://detroit.craigslist.org/wyn/mcy/3102914716.html

There it is. What do you guys think.

[AtvKid4Eva]

the only way to really see whats going on is to take the clutch side cover off. you should see the problem when you pull of the cover. Sharp looking bike!

[HndaRcing8]

Alright doing it today and well see what happens.

[400exwhipper]

My clutch sticks after a couple days of sitting its a tusk clutch with HD springs, all I Do is warm up the bike and hold the rear brake, rev it once with the clutch in and grab first gear, clutch pops right loose every time good as new

[Stickman400]

This doesn't help you with your problem at all but that FMF silencer is deff. not made for a 400ex. Someone custom fabbed the mounts up on that. I wouldn't be hitting too big of jumps or it looks like to will beat the crap out of it. Other than that it's a nice quad.

[HndaRcing8]

Thanks for all the help guys. Still figuring out what's up, not sure If it has a stock clutch or what.

[jgar]

Probably has grooves in the basket. Looks like a good deal.

[HndaRcing8]

With mechanically talent, how hard is it to pull the motor to change out the clutch on the 400s?

[CJM]

Dont gotta pull the motor, just the righthand outer case (brake lever side). Pull the case cover off and voila you see the clutch. The pressure plate comes off and you can remove the basket with an impact gun or by hand if you wish.

Its a rather easy job.

[HndaRcing8]

So looks like the clutch basket has groves in it, reason why my buddy took a look and said I should replace. Now what brand or parts should I be looking at for this bike, Has 429cc built motor, Looking for a heavy duty race clutch? Or what would lead me in right direction on this one.

[CJM]

Stock basket should be fine. If its not grooved to badly you could try and file it down, it does work sometimes.

Personally I like my GT Thunder HD clutch setup, got it on ebay for 200. Some like the tusk HD setup as well.

[jgar]

Like CJM said if the grooves are mild you can file them out. But if you already have the basket out I would just replace it. A stock basket may groove up again if a few years. But by that point you would be replacing the clutch anyways. A aftermarket basket will be more durable. I have had great luck with the tusk clutch kits.

[HndaRcing8]

I never got the basket out, having hard time figuring out how, don't want to **** it up, should it just pull out? Also the basket has some good amount of groves on it, running finger over it it is pretty bumpy. Also I went to drain oil, barley anything came out. Took the clutch case off and hardly anything was in it oil wise, now there was not a gasket either. What oil should I run with a bored motor? Another thing isthat I found two houses that happen to be attached to this thing under the seat (don't know name cause don't know what it is, I can upload a pic) but the both are connected to it and I found them stuff near the tear shock. When to stand the quad straight up and bam, gas started coming out of them. also if you where to pinch one of those lines the other one would have gas come out, but only one was leaking gas while standing up. On main ground level, nothing. Help!

[junior636]

You have to drain the oil from the oil tank and the motor if you are changing the oil. The oil tank is the tank up front where the dip stick is. The hoses are just overflow lines for the carb, they should be draining gas if you tip it up, need to shut the gas off if you are going to put it up on the grab bar.

[HndaRcing8]

Hah thanks man. You need that special tool to remove clutch basket? Just looking to get good quality parts like for the basket and clutch, also spark plug what to run ans gap?

[Stickman400]

Not having a gasket on that clutch cover side is not a good sign, be sure to put one on it whe you re-assemble it. Everyone on here recommends and runs Rotella 15-40w in all different kinds of motors, so it'll work for you. That is a weird place to have drain hoses for your carb., I would assume they are vent hoses, but nonetheless be sure to turn your gas off like recommended before tipping it up. You shouldn't need a special tool to remove the basket, you just need to put an impact on the big center nut and then it should just slide off. The nut is staked so be sure to re-stake it when you re-install it. And finally a stock NGK plug (DPR8Z) is fine to run in these, I believe the gap is .024-.028

Hope that answered all of your questions, be sure to ask more if you are unsure about something. Everyone here is more than happy to help.

[HndaRcing8]

All the information and help is really appreciated ! Thanks so much!

[jgar]

You may also want to put it in 5th gear before you start. This will keep the basket from spinning. Sometimes I will also put the brake pedal back on so I can kneel on it while replacing a basket.
Like stickman400 said make sure you re-stake the nut. Also I have not been able to find any torque #'s for the bolts that go through the springs. What I do is when removing the bolts count the revolutions and replace accordingly. Find a manual that you can download. It will walk you through the process in great detail.

[HndaRcing8]

Thanks! Also found a write up on it and I have been following that, I ordered a owners manual also, mean time, can some one tell me how many quarts this motor holds, matter if its a big bore or stock?

[Stickman400]

Yea there isn't a torque value for the bolts that go through the springs. I just use a 1/4" ractchet and hand tighten them until they are snug. And it doesn't matter if it's a stock 400 or a 440, it's all gonna hold the same oil. It's says 1.8 qrts. in the owners manual, but sometimes that's too much and sometimes not enough.

I usually put in 1.5 qrts., then check it and add until it's up to the hole in the dipstick. Then start it up and let it idle for 5 minutes and then turn it off and let it set for 3 minutes then check it again and add whatever it needs to get it back up to the hole again.

[HndaRcing8]

I got clutch case out, now the groves are where the slots are for the clutchs? Mine are kinda bad should I bother filing it down? Also how do I tell if my clutch plates are good and or bad? - I'm new to this so bare with me please. If I had a bad clutch fork? Will this empty my pockets or need more work that needs skill?

[Stickman400]

Welll usually if you run your finger across the grooves and you can feel them then you can either file them down to help or you can buy a new basket. A picture would help us tell what you should do. And you can measure the thickness of the clutch plate to see if it's still in spec. or needs replaced.

[HndaRcing8]

I have few pics but won't let me upload, if your interested in seeing and helping out I can send via email or text let me know please! Mitchv07@yahoo.com or 1248 224 1816 thanks.

[HndaRcing8]

That nut that holds it on also looks jacked up on theoutside, don't know about steaking a nut but also the threads that it goes in, the first 4-5 threads are like chipped right off, but still threads on good. So lost at this point.

[CJM]

Upload the pics to tiny pic and link them here.

[HndaRcing8]

I'll be able to hop on a computer in a few and upload some good pictures.

[HndaRcing8]

Well here are a few pictures, also the pressure plate looks good, the clutch basket has groves, and the middle second clutch don't know proper name it has groves also and the pretty warped at the bottom, and if you pull it out and turn it around and look around it looks like it was took to a grinder and chipped up, also i can upload picture of that if interested.

http://i48.tinypic.com/hvcqbs.jpg

http://i48.tinypic.com/fc8vfa.jpg

http://i45.tinypic.com/8fx5.jpg

http://i45.tinypic.com/23rvj1z.jpg

Heres that nut that looks smashed up
http://i47.tinypic.com/2mdrxnc.jpg

[HndaRcing8]

Everything looks alright?

http://i50.tinypic.com/24xktnl.jpg

Good or Bad? Nut still threads on.

http://i49.tinypic.com/20uyd5i.jpg

http://i46.tinypic.com/3038xud.jpg

http://i47.tinypic.com/14lb15.jpg

http://i50.tinypic.com/51eazd.jpg

http://i50.tinypic.com/51eazd.jpg

http://i47.tinypic.com/14ac6df.jpg

[jgar]

At this point I think it would be foolish to reuse any of those parts. You can get a stock basket on ebay for 25-50. Rocky mountain atv has a good clutch kit with springs for around 60. You might be able to find the nut on ebay. If not a place like bike bandit will have one.
If you try to reuse any of those parts and the system does not work as it should you have to take it all apart again. Walking out of the woods is not fun. :mad:

[HndaRcing8]

Thanks well that's my plan. Now I was taking the back tires off and guess what, stripped lug nut. Got it off and thread is ****ed. So anything I can do?

[CJM]

You need an entire hub or you can buy the lug stud, as in here: Lug stud (http://www.ebay.com/itm/TRX250X-TRX300EX-TRX250R-TRX400EX-TRX450R-TRX450ER-REAR-WHEEL-HUB-STUD-BOLT-/400274612863?pt=Motors_ATV_Parts_Accessories&hash=item5d3239e27f&vxp=mtr)

[TheAwesomehonda]

The nut that holds the clutch boss on needs to be replaced everytime it is taken off. Your supposed to use a punch to bend the nut into the groove on the shaft.. That keeps it from loosening up on it's own.. So they did what they were supposed to last time that clutch was installed.

[ride red 14]

The inner clutch hub looks worn out too. You can see a lip on the outer edge. I would put the whole clutch in it if i was into it that far. Basket, inner hub, pressure plate and clutch kit. Do it right once and you will not be back in there for a long time.

[HndaRcing8]

Hah makes sense! Duh! Also found two new rear hubs for 35$

[CJM]

Originally posted by TheAwesomehonda
The nut that holds the clutch boss on needs to be replaced everytime it is taken off. Your supposed to use a punch to bend the nut into the groove on the shaft.. That keeps it from loosening up on it's own.. So they did what they were supposed to last time that clutch was installed.

Ive reused mine 2x now and a friends as well. It does help I used an impact to install it and restaked it.

[TheAwesomehonda]

Originally posted by CJM
Ive reused mine 2x now and a friends as well. It does help I used an impact to install it and restaked it. Ok i stand corrected. Wouldn't the nut be in the same spot as the last time it was tightened so you would be staking the same spot?

[HndaRcing8]

I got my list for every thing I need, all for 300$ in parts to get her going, also including full tune up and some misc. Thanks for the guidence and all the help I really appreciate it! So I'm 1200$ into this quad and feel good about it! I'll let you guys know how it goes and any other problems. Just need to look at a write up on adjusting the clutch cable!

[CJM]

Originally posted by TheAwesomehonda
Ok i stand corrected. Wouldn't the nut be in the same spot as the last time it was tightened so you would be staking the same spot?

Not necessarily. However if you are careful unstaking it you can reuse it. You can hardly tell where it was staked before on mine. The spot I staked is in slightly different spot.

Mostly I think the impact gun is what makes it stay on lol.

[HndaRcing8]

So when I was taking the the Tappet Adjusting Cap off cylinder head to adjust valves, I had two of them crack... Common or what?

[CJM]

The 24mm caps, yea Ive seen it before. Usually its b/c someone before you tried to get them off another way.

Friend of mine looked like they took a screwdriver and hammer and smacked them off.


FYI: Dont make them to dang tight!

[HndaRcing8]

Smh there 16$ a piece.

[HndaRcing8]

Found a write up on adjusting valves, never done it before. The two valves on carb side have no play and the ones near handlebars have some play. This is me just pushing on it with finger. Not undoing the nut or screw. Any advice?

[Stickman400]

Intake (Carb.) side need loosened slightly if that's the case. The intake side always seem to get tight before the exhaust do anyway so you are ok, nothing to worry about.

[HndaRcing8]

Thanks man, I owe you for the help. Been trying hard to get this spark plug out, a 18mm thin wall won't work, nor a 13/16, wont fit between heads. It's built 426 I don't know if its a stock head... Hmmm. What's should i do?

[CJM]

You need the tool from honda, a special socket or take an 18mm socket and grind all around to fit in the head.

[HndaRcing8]

Alright thanks, I'm going to try that!

[HndaRcing8]

So I took a 18mm socket and grinded it all around down where it clears the head, won't fit still. To small for the nut on the plug I think! So frusterating. Giving this Honda place a call tomorrow.

[jgar]

The tool comes with the took kit when you buy a new ex. You can get the tool kits on ebay for next to nothing.

[HndaRcing8]

jgar - http://www.rockymountainatvmc.com/oem-schematic/3

Would this consist on that kit?

[jgar]

The link just sent me to rmatv.

http://www.rockymountainatvmc.com/p/43/-/171/954/-/1486/Motion-Pro-Spark-Plug-Socket/400EX+PLUG+WRENCH

http://www.ebay.com/itm/05-Honda-TRX-400ex-TRX400ex-Toolkit-Tool-Kit-28-/251114544430?pt=Motors_ATV_Parts_Accessories&hash=item3a7797dd2e&vxp=mtr

http://www.ebay.com/itm/Tool-Tools-Kit-OEM-TRX400EX-TRX300EX-TRX400-TRX300-TRX-400EX-300EX-400-300-EX-/200790044984?pt=Motors_ATV_Parts_Accessories&hash=item2ec004f138&vxp=mtr

[riotact]

Gearwrench brand 18mm deep well socket from Autozone is what I use and its alot cheaper then the tool kit.

[CJM]

The tool form honda is like 10 bucks guys.

[HndaRcing8]

Haha thanks guys!

[HndaRcing8]

Haha thanks guys!

[powerbomb400]

And it is well worth the money. I bought one for home and on the road. The one from Honda has a allen wrench welded on top so you can use a gear wrench with it.

[HndaRcing8]

Alright well I got everything pretty well set up on the quad now, just waiting on my Tusk clutch kit to come in on Tuesday, was on back order so i had to find another seller on ebay. The problem I'm running into now is really struggling to find out how to properly hook up the clutch cable, I was messing around with it to see, and I guess what works best for me is seeing it in pictures. If any one can upload few pictures of the cable at the lever (witch is simple I know how to do that) but what's getting me is where it hooks up to the lifter arm! Getting anxious and excited! Putting the new cultch basket and inner clutch in was easy, made sure I rememberd to re steak the nut! Just waiting on this darn clutch kit! Thanks yall.

[300exBorg]

look for a manual online (free to download) and that will have pictures for you. it'll also show you how to replace it step by step i'm sure.