honda 400ex clutch question

[dodgeram14jr]

I have an 01 honda 400ex. I went riding today and notice when I left the clutch out it grabbed when I had the clutch lever almost all the way out. I looked at the adjuster on the bars and it's not turned out. I also looked at the adjuster on the motor and there's more threads toward the end of the cable that's facing the rear of the quad than there is facing the front of the quad. Or do I need a new clutch? Any help is appreciated Thanks Dean.

[Blodg]

You need to check how much free play you have in the clutch lever before it engages. In other words, when you start pulling in the clutch how far does the end of the lever move before it starts moving the lever on the side of the motor.

[dodgeram14jr]

I just went out and checked as soon as I move the clutch lever the lever on the motor starts moving also.

[Blodg]

You are supposed to have around 1/2" to 3/4" of free play at the end of the lever. So yours could be engaging the clutch too soon and causing premature wear.

What do you mean when you said it."grabbed" when the lever was almost all the way out? Like chattering or the quad lurching forward?

[dodgeram14jr]

When I say it grabbed I meant that the quad started moving when I left the clutch pretty much almost all the way out.

[dodgeram14jr]

Any other suggestions or help? Thanks

[Blodg]

With no free play and the clutch not engaging until the lever is all the way out could indicate that the clutch plates need replaced. But normally you would feel some slippage when they need replaced. Do you feel it slipping at all? There is no adjustments that will help if you have no free play it is already engaging sooner than it really should be as you let the lever out.

I know with my good clutch with proper adjustment the lever is maybe 3/4 of the way out before the clutch starts engaging and the quad starts moving. I will pay more attention when I warm it up for an oil change in the next few days.

[dodgeram14jr]

When I run it after I let it warm up this past weekend it seemed like it was slipping alittle. But kinda cleared up. When I shut it off I kept some speed and left the clutch out and it drug the tires I'm not sure if that means the clutch is ok or not. If yours is left put at 3/4 and engaging mine around that also maybe alittle farther. So would u suggest replacing the clutch? Thanks for the help

[dodgeram14jr]

Oil wouldn't have anything to do with it? I'm running maxima 10-40 atv oil. I been running it since I had it and never noticed a problem

[ride red 14]

It's time for a clutch. Probably can get by with just putting the fibers in.

[dodgeram14jr]

Ok if I were to replace everything for piece of mind what all needs changed to have everything right? Thanks for the help.

[ride red 14]

All you need is a set of clutch plates and a cover gasket. Put the plates in and it will solve your problem. If the cable is hard to pull, now would be a good time to replace it too.

[dodgeram14jr]

Ok thanks for all the help I appreciate very much. My clutch is very smooth and easy to pull so I don't think it needs replaced right now.

[Blodg]

Ok tonight I paid attention to the clutch movement while riding around the yard to warm the motor up for an oil change. As I slowly let the clutch out the quad starts moving when the lever is about half way out and by 3/4 of the way out I would say the clutch is fully engaged.

[dodgeram14jr]

Ok so I may not need a new clutch mine may just need adjusted. Which adjuster should I use the one on the handle or the one at the motor? Thanks for the response

[Blodg]

Dodge, I already told you that if you have no free play in the lever then there is no adjustment that will help. Your clutch is already engaging sooner than it really should.

If you want to try adjusting then turn at the handlebars to get 3/8" to 3/4" movement in the end of the lever (free play) before the cable engages the clutch. If the adjustment on the lever is not enough then you need to adjust on the side of the motor.

[dodgeram14jr]

So I adjusted the cable down on the motor and now it engages about half way. It's better than it was before I adjusted it. I'm gonna take it and ride this weekend and see and evaluate.

[dodgeram14jr]

So I replaced the clutch plates and fibers and springs. I wanna adjust my clutch cable. My question is with the free play will the lever on the motor still be moving when there's free play?

[ride red 14]

Yes. Anytime you pull your clutch lever the clutch arm will move.

[dodgeram14jr]

So how do I determine the free play? Should the clutch be fully engaged by half way out?

[ride red 14]

Maybe. Depends on preference. For xc racing I like mine to engage about halfway out and be fully engaged by 3/4 out. That way on hills when I want to slip the clutch a little I only have to pull it in about a 1/4 to get it to slip.

[dodgeram14jr]

Ok I was just concerned about the free play. So you don't run much free play? I just don't wanna burn up my new clutch

[ride red 14]

Don't blame you. As long as when your riding along under throttle and you can pull the lever in some without it slipping you should be fine.

[dodgeram14jr]

Ok I appreciate the replys. I will give it a shot.