XR400 clutch

[dixiegooner]

Yesterday I replaced the clutch on my '03 XR400R. Nothing more than a 30 minute job I guessed.

After wrestling the cable from the lever I quickly had clutch cover and clutch removed.

Afetr fitting new clutch I then offered the cover back upand ensured that the lever within the cover was correctly lined up to pick up the Clutch lifter pin.

When all back in place there is no resistance on the lever and feels as though it is not picking up the pin and therefore for not engaging the clutch.

I have now taken it off and put it back on several times, but still am having no luck.

Can anyone advise me where I am going wrong?

[416cc]

I would go back over what you have done inside the clutch housing.Also check to see that you have replaced the right number of friction plates.

I have fitted heavier duty springs to my XR400 clutch.I got them from PDQ and they are the same as for the old Fireblade.They don't make the lever too much heavier but I am still on the original plates even though the bike has had a hard life in my hands.

[jasonbc]

Yesterday I replaced the clutch on my '03 XR400R. Nothing more than a 30 minute job I guessed.

After wrestling the cable from the lever I quickly had clutch cover and clutch removed.

Afetr fitting new clutch I then offered the cover back upand ensured that the lever within the cover was correctly lined up to pick up the Clutch lifter pin.

When all back in place there is no resistance on the lever and feels as though it is not picking up the pin and therefore for not engaging the clutch.

I have now taken it off and put it back on several times, but still am having no luck.

Can anyone advise me where I am going wrong?

When you took the clutch cover off did you disturb the actuating rod from the housing as there is a small return spring on the bottom of the rod which drops out quite easily this spring is responsible for the rod retuning to it's back position if it was missing the rod good go forwards with no resistance on it..