Honda ATV Clutch Replacement - 400EX | Partzilla.com
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- Опубликовано: 13 сен 2024
- Honda clutch removal and clutch install. Buy all the parts for this clutch replacement on Partzilla.com: bit.ly/ATV-Clut...
In this video, John shows you how to inspect the clutch drum and clutch disks and plates to determine whether they need to be replaced, how to oil your disks and plates, and how to remove gasket material. He also shows you how to remove the brake lever, clutch cable, reverse cable, send and return lines for oil tank, and 8mm bolts that hold on the TRX400EX side cover.
To do this job, you’ll need to drain the oil. See how to change the oil on your TRX400 here: • How To: Honda ATV Oil ...
Need to adjust the clutch cable on your Honda TRX400? Here’s how to do it: • Honda ATV Clutch Adjus...
Read more about how to do this job step by step: www.partzilla....
VIDEO HIGHLIGHTS:
Removing the brake pedal - 1:00
Disconnecting the clutch cable - 1:40
Removing the oil pipes - 2:00
Removing the clutch cover - 2:20
Removing the clutch pressure plate - 3:00
Removing the clutch plates - 3:15
Preparing new clutch plates - 4:20
Replacing the clutch plates - 5:00
Replacing the pressure plates - 5:15
Replacing the clutch cover - 5:20
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In the video we’re working with a 2007 Honda TRX400 EX, but you may have similar steps for your Honda ATV. If you’re not sure whether these steps apply to your machine, leave a comment and we’ll get back to you.
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This guy has got all the snap-on goodies! Thank you for the help partzilla!
“Once the ool is out of the machine”
Can you do a timing chain replacement
We sincerely appreciate your videos as they are a huge help; however: you always seem to neglect to mention the torque spec's for each bolt or nut. Also, whether to use blue or red lock-tight or in the case of cylinder or cylinder head studs we should apply a small amount of oil to the threads. Thank you for your time and commitment to helping all of us d.i.y. guys trying to save money and stay out on the tracks and trails.
your videos have been a big help! I recently put a new clutch on my 400 and this video helped me. I got it together and the clutch was working great shortly after I put a timing chain on. Just reinstalled the clutch after installing chain and now it is not engaging. took it apart and put it back together a few times to see if that makes any difference and it has not. My springs are fine. Clutch disk are in right. Lever feels like it’s engaging but the clutch just isn’t working right. Any idea whats going on?
It's not as easy at the guy does it but trust me just work through it you got it 👍👍
Can you explain the disc for the clutch like witch one goes first and the ending ones
getting ready to do a replacement was wondering if there was a certain ftlbs the springs require thank you!
+Cody Simmons The Honda Service manual does not specify a torque amount specifically for those bolts. They do have a generic torque table based on the type of bolt. In this case those five bolts are 6mm flange bolt with a 10mm Head and call for a torque of 9 ft-lbs. Good luck on your project!
this video saved my clutches!!! I didn't offset the last friction disc before installing the pressure plate. I only ran it like that for about 25 seconds in neutral then had it in first with the church in for about 10 seconds. Will that 1 friction disc be ok? i hope it will be. If I can't use that last disc after I correct it please let me know. thanks you
What’s the torque for those bolts??
What was the symptoms that lead you to replacing the clutch? I have the same atv, 07 400ex, and gears don't engage (click) until I'm about 3/4 out of the clutch. That's not a clutch issue correct?
Hey man did you ever figure this out? Got a four wheeler doing it now
Can you do a video on cam chain replacement?
We'll put it on the to-do list!
Partzilla I put my clutch and everything back in now my cable is loose and my clutch is not engaging please help
Thank you!
I just replaced the clutch plates in my 2001 400ex. it was starting to slip in high gear when I would romp on it. when I tore into it I noticed the last friction disk was not offset one notch like you mentioned in the video. could this be the cause of the slippage? what is the reasoning for having the last friction plate offset from the others?
+Nate Fuller That should have not cause the slippage. The plate is offset is done to help reduce “judder” during clutch engagement. The last plate is the first to engage.
I just replaced the clutch basket in my 2000 honda 400ex and if I pull in the clutch and put it in first it takes off like the clutch isn’t disengaging could it be because the last fiber plate isn’t offset?
about how long should i soak the disks in oil for
+Drones USA An hour will do it.
I've had to adjust my clutch a lot.It doesn't engage until my clutch lever is at least 7/8 of the way in.Do I hav to get a new clutch ?
how do i install the reverse engagement arm? i took the cable off and cannot figure out how it goes on.. thank you .
I know I need an 1/8" of play on the inside of the clutch lever, but what about the bottom adjustment?
Honda 250 2007 model I fix the calsch not working how to check peless helf my sir
Hello! I was changing my clutch but when I removed the cover the reverse lever inside came off, is there any idea on how to put it back?
What do you mean be off by one tooth on the fiber desk
What about the torque on putting the 8mm bolts back?
Do u Have any videos of the flywheel replacement
How should I break in a 2003 Honda rancher 350 with a new centripetal clutch
I have a trx 700 is it the same can’t find no videos on it
I have a problem with the neutral light on my 2000 400ex the previous owner said he changed the clutch cable and the neutral light just blinks and I have to be moving the clutch pedal so the light turns on.
OMG, when I was taking the cover off the "reverse spindle", (I don't know its proper name) came out. It's the metal spindle located below and on the lower left of the clutch pack. The reverse cable connects to it.
How do this go back in?
Should the puller pin be able to move in and out easily?
Which pin are you referring to? None of the pins in this video should be very difficult to remove.
Partzilla I was referring to the clutch puller pin I cannot get it to line up properly
Sounds like you're not getting it at the correct angle to hook or grab it. It shouldn't move around much. They can be a little tricky sometimes. Keep trying, you'll get it.
Do you need to replace springs too if you replace your clutche
You don't have to. Clutch springs last a long time. The flip side to that is that they are cheap, so while you're in there, if you want to toss new ones in, it can't hurt.
Can you put a 400 EX clutch on a 300 EX
Ok thanks
as I was removing the housing I found a spring laying into housing would you know where it goes
+Nernie Booth Thats a bit scary. Can you send a pic of the spring
+Partzilla.com I'm not sure how to send a picture on here but i can try
+Nernie Booth actually i see where it goes now with further review of the video it goes on the clutch arm
Also how much movement should the lever on the clutch case have when you pull the clutch in?
1/8 of an inch from the resting position. in your manual will say (could possibly be more or less)
Torque specs for pressure plate bolts?
I hope you will see this... I have an 05 400ex that I picked up yesterday, and when I got on it I realized it didn't have the power that my old 400ex did, and it won't spin tires or start out on a hill, and really just doesn't want to go. Do you think it may be the clutch??
Does the unit rev out?
Carb issue
What do u mean when u say last fiber disk needs to be off one tooth and how do u tell ur of one tooth? How much do i torque the bolt with spring on it? And how much do i torque the cover bolts? And will this exact step be the same for a 2008 honda trx 400ex
Instead of lining up the last disc with the others, you move it over one notch. If you look closely on the video, you will see how it goes. The spring bolts don't have a torque spec. Just tighten to stop and snug them. Don't tighten them too much because they can snap. Cover bolts are 8 ftlbs. No change on 2008.
I like the vids, but you sometimes explain things as if we already know what you mean. What do you mean to be off by one tooth on last fiber disc? I don't follow.
They all go in the same until the last disc, just rotate it back one notch.
@@PartzillaParts the fiber discs have one "tooth" with writing on them should that be facing you and all them in the same slot except the last one being a notch back?
What is the the total labor time for this? Also if the plates are stuck together does that necessarily mean they need to be replaced? Or just soaked in some oiland put back in?
How can you avoid having the plates getting stuck together? Thx for your help!
Clutch labor is about 3 hours. The plates will stick a little because they are covered in oil.
Partzilla Thx! My clutch cable won't move and the dealer where I've taken it for service says I need a new clutch. They are offering to install a kit. What kinds of wear should I look for? Is it common for the plates to just get stuck because of low oil in the machine? Don't want to get raked over the coals for a. ew clutch if I don't need one. Thx!
You can always follow the video and inspect your clutch. If you had low oil for a duration of time, you will see scorching on the plates. Otherwise, you will be able to see noticeable wear if the clutch is bad. Just pull the discs out and check them out. If it needs replacing, you can order a clutch pack and get it done.
Partzilla hey on a 2002 ex400 is there a gear where u keep going like 6th I mean u can't ride that gear forever I know that but any feed back will be great :)
So do you not replace the fiber plates with the metal or steel ones? (Clutches)
You can reuse the metal plates if they are still in good condition, but we recommend replacing them all at the same time.
My second gear won't catch I'm woundering if that might be one of those disks are broke
Check to make sure your clutch is fully disengaging first. That is usually the simpler solution. If the clutch is disengaged and it still won't, then it's time to dig in.
i have a 97 trx300ex honda is the clutch replacement the same
yea
After doing this my 400ex is still leaking oil from the new gasket I put on should I use rtv or hondbond to seal it up ?
You can, but it's a sloppy fix. It's better to try and find out why it's leaking. Maybe some old gasket is still there?
My clutch lifter arm moves up and down when the motor is turned on. Is there a seal or someting that I need to change? thanks for the answer in advance.
Sounds like the circlip is missing or dislodged.
What is the torque value of the 5 bolts that hold the springs to the pressure plate?
There is no torque spec for the spring bolts. They are positive stop, don't crank on them, they will break.
how would you go about changing the drum? thank you
+Eric Singhaus Only one more bolt needed to be removed. The clutch center nut has a retaining washer that has to be bent down away from the edge of the nut before you can remove it. Keep in mind that this nut needs 80 ft-lbs when reinstalling it.
is the last disk because of reverse or is it the same for all 400ex models because my 04 doesnt have a reverse
All the same process, regardless of reverse.
When would I need to replace the basket? Is it when there’s deeper grooves than usual wear or??
You will see ridges on the outer edges, like steps. It's explained in the video.
thank you
When i pulled the side casing off a little spring fell out that has 2 straight lines coming off it instead of having hooks. Its on a 03 400ex would you happen to know where it goes?
Kyle Ellis I'm late to the party but I'm guessing it was the spring that goes on the clutch rod on the inside of the case.
how much is the clutch bowl (not sure of actual name)? when I replace mine I feel as if I may find damage in there. also what kind of aftermarket clutch would you recommend?
93trx300ex- fmf exhaust and header, stage 2 carb kit, performance cdi
clutch basket..!
If anyone takes the cover off and notices a miscellaneous dowel with an oringe and is confused it is the goes in the case where the oil pipes are, took me about an hour and a half to figure that out
I'm actually confused by what "with an oringe" means.
I have a 2001 honda 400ex trx, but soon as I squeeze the clutch handle in a drop it down into 1st gear the atv jumps forward and shut off....any help on this issue
Clutch!
i have a 2006 honda trx400ex the only slips when its cold then it worms up and if fine any thoughts?
Hello Seth. It seems like it may be time for a clutch replacement. Clutches can slip like this when the exposed face of the clutch discs become glazed over.
Or it could be as simple as the engine oil. what type of engine oil are you using?
Do you have videos of transmission replacement?
We don't have any up yet. We will add it to the suggestion list and see if we can get it done. Thanks for watching!
Partzilla any trans video yet lol
What should the ft pds be for the cover screws
Those don't have a specific torque spec, however, there is a general torque spec of 9 ft-lbs for that size bolt. So that's what we would run with.
@ partzilla I was riding my 2007 trx400ex and my clutch cable snapped while riding I stopped and noticed that the clutch lifted arm is very loose to push into engagement my friend was riding his bike (2005 trx400ex) with me when this happened and we tried pushing his lifter arm to engage it and it was very hard. Do you think my clutch plates went out I never had a problem with it slipping before. Can you please help me ?
It sounds like you need to inspect clutch and arm.
My actuator arm wont grab the lifter! How do i fix this? I cant get the cover on unless my actuator is pointed away from the clutch, and then it wont turn
Narwal Ninja same did u figure out how to fix it
Hi partzilla. I have a 04 trx 400ex. All gears shift as they should. Except for getting it in neutral. It gets really hard and shifting up it'll got straight to 2nd and shifting down it'll go into 1st. But works everytime when it's off. What could be my problem? Thanks in advance
Forgot to mention that it also has reverse.
Check fluid levels. If it looks ok, then it might be time to inspect the clutch and transmission.
Make sure chains not to tight when rear suspension is loaded like when someone is sitting on it
Hey my bike is jerks when u put it in gear but when u release off the clutch it doesn't move but you can push the bike and it move while in gear like it's in neutral what could that be
Either, cable adjustment, bad clutch or a tranny issue.
I got a question. So I have to 2003 400ex's and one clutch seems to be very stiff and the other normal. I replaced the clutch cable but still its very stiff. How do I fix that*
+Rory Reyes I would have pointed you to a cable as well. Since that is not it, I would think that the clutch basket might be the issue or the clutch arm pivot arm needs attention.
+Partzilla.com okay thanks
Is this the same way for a 99 to 04 400ex?
It's the same process.
How many foot pounds should the 8mm bolts be when reinstalling
Those don't have a specific torque spec, however, there is a general torque spec of 9 ft-lbs for that size bolt. So that's what we would run with.
Also One las question do I still offset the last plate if I don’t have reverse
My Honda 400 ex will go in first and then in second it feels like the clutch keeps geting pulled in
Luke Fausett it sounds like it’s slipping. Im a little late though 😂
is it the same for a 06 trx300ex ?? or similar
Same process. Different parts.
Would I have to replace my Clutch if yesterday i was riding and all of a sudden i turn on my atv, put it in gear and the tires budge a little and I give gas and it doesnt move. Can you please help me! Thank you!!!
+David Kwak What you are describing could be the clutch. Did you check the cable play to make sure it's not too tight? You need to have a 1/8" gap between the edge of the clutch lever and the lever mount as you start to pull the clutch in before it engages. Look at this video to adjust the clutch play: ruclips.net/video/nBvNbhGscM4/видео.html&feature=iv&src_vid=xhyx3QD1O9g&annotation_id=annotation_780072729
+Partzilla.com When I tried moving the clutch got softer then it used to be
In first gear my quad rolls forward very slightly when the clutch lever is still engaged. What could be the issue?
Adjust the lever/cable so it fully disengages.
Partzilla what if it doesn’t after that
Then you either need to replace the clutch cable or inspect your clutch.
Did you figure it out? Mine was doing the same thing and I took everything apart and cant see an issue. The clutch basket has very small grooves but everything else looks good.
I can’t get my clutch cover off at all
In a couple of days I'm looking at a Yamaha warrior it's real clean but the owner says it needs a clutch and valves adjusted and I wanna make sure I'm not buying a junk motor so how do I tell if the valves do need adjusted will it make noise or what?? And how do I tell if the clutch is bad he said sometimes it don't grab. Sounds like clutch is bad but I just wanna be on the safe side. Any help will be appreciated.
Scott Ohler I might be late but I suggest getting a working machine
Valves can be bad without showing a bunch of symptoms. Ask him why he thinks the valves are bad. Ticking, backfiring are common symptoms. For the clutch, when it's running, put it in gear, see where it engages and hold the front brake while easing the clutch out. If the clutch slips before the bike stalls, then it has problems. Just a couple things to give it a once over.
Partzilla he said it's ticking pretty loud is that something to worry about? I just don't want to buy a quad with a junk motor.
Just indicates that it may need a valve adjustment. If the ticking is more of a knocking, then expect a lot more work.
Scott Ohler
Sounds like a piece of 💩, keep looking, don't buy the first machine with issues.
I picked up a 2007 Honda 400ex turn key for $800. They're out there, just gotta shop around & take your time.👍✌
How can you make a video and not specify torque specs
BEWARE ..!!!! DO NOT TURQUE THE BOLTS DOwn .. I listened to this dummy and snapped a bolt !! Just tighten till snug and then one full turn in star pattern
change speed to 2 elmer j fudd here talks to sloooooow
Hello, I put a new timing chain on my 400ex and I bought a gasket from partzilla.com and the clutch cover leaks a lot, any thing you recommend? please reply!! I rebuild the top end, and only put new seals on the head. I followed your videos and it runs mint. just leaks in the clutch cover.
by the way its a 2000 400ex
Harrison, if it's leaking at the clutch cover, it's possible that it wasn't cleaned well enough to get the old gasket off, the gasket got pinched or it wasn't torqued down right. Those bolts should be torqued to 9ft lbs. You may have to pull it off and see where it's leaking and redo the gasket. If you want the cheap fix, get some high temp RTV and seal the area that's leaking.
First we are going to drain the oil ... if you need help doing this ... please turn off this video immediately! lol
I recently bought a 05 400ex and it ran fine for about an hour or so, then the clutch wouldn’t work so we adjusted the cable and it ran but after we adjusted it, it wouldn’t move until the clutch lever was almost all the way out, and if you are going down the road and get on the throttle, it will rev way up and then take off, please help I would really appreciate it, thanks.
it's likely you need a new clutch.
as I was removing the housing I found a spring laying into housing would you know where it goes
Nernie Booth me too, did you ever find where it goes?