XR 400 Clutch

[jasonbc]

[QUOTE=rkw64;480018]Hi i have replaced both parts of the clutch lifting mechanism and wire filter with no joy
Richard[/QUOTE

Have you miked up the clutch plates and measured the length of the clutch springs? to check they are with in limits

[rkw64]

[quote=jasonbc;480022]

Hi i have replaced both parts of the clutch lifting mechanism and wire filter with no joy
Richard[/QUOTE

Have you miked up the clutch plates and measured the length of the clutch springs? to check they are with in limits

Hi the clutch plates are not mixed have new springs even tried heavy duty springs which inproved the problem a little but no thing like it should be
Richard

[Xman]

Check the nut that holds the clutch basket on the the shaft has not come undone and letting the basket move away from the operating mechanism.
You will need to undo the clutch spring bolts and take take the clutch apart, while you are in there, take a close look at the springs, operating rod and friction discs, for serviceability. Is the clutch genuine Honda or a pattern part?

[rkw64]

Check the nut that holds the clutch basket on the the shaft has not come undone and letting the basket move away from the operating mechanism.
You will need to undo the clutch spring bolts and take take the clutch apart, while you are in there, take a close look at the springs, operating rod and friction discs, for serviceability. Is the clutch genuine Honda or a pattern part?

Nut is tight New genuine Honda clutch the clutch works fine when cold
Richard

[Xman]

You say you get increased free play at the lever when the clutch heats up, I get this a sometimes when riding hard, but it will be normal again when it has cooled down, so I have stopped adjusting it constantly. Is this the same in your case?

[XR Mad]

Sounds like the clutch plates are warping with the heat and expanding the clutch pack which pushes out the pressure plate giving you the freeplay. Put the metal plates on a piece of glass if you dont have a surface plate and go around them with a feeler gauge to see if their starting to warp. service limit is 0.30mm.

[rkw64]

You say you get increased free play at the lever when the clutch heats up, I get this a sometimes when riding hard, but it will be normal again when it has cooled down, so I have stopped adjusting it constantly. Is this the same in your case?

yes that is what is happening but i can lose the lever so i can't stop the bike

[rkw64]

Sounds like the clutch plates are warping with the heat and expanding the clutch pack which pushes out the pressure plate giving you the freeplay. Put the metal plates on a piece of glass if you dont have a surface plate and go around them with a feeler gauge to see if their starting to warp. service limit is 0.30mm.

I have put metal plates on glass and all fine I'am at aloss on where to go next
Richard

[416cc]

It sounds as though the oil's not circulating quickly enough...I know that it's a long shot but have you checked the small oil filter (#1 on the fiche)at the bottom of the frame down tube? If clean check to make sure that the braided hose isn't twisted as this can constrict the oil flow.

honda frame partsmanual fiche xr400r 99 xr400 partslist

[jonnybgood]

Was just about to start a new thread on same issue when I saw this one. I get exactly the same problem when riding hard but slow sections off road. The clutch heats up to the extent I no longer have a clutch - I have changed the plates (not the metal ones) and put in HD springs - I run on rock oil - the problem has always been there - it really doesnt take much to put the clutch out of action - a tricky section of more than a minute or two and thats it - still looking for a solution.