Question about 2002 Honda CL 400

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Clutch Live in Cambodia....3 times the mechanic(Irish) has replaced the metal plates, and entire system once....still pulls when in N, and very difficult to shift up....down is easier, but still difficult at times. Help! This thing is killing me.

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  • Patrick Dennehy May 11, 2010

    Might be the wrong clutch kit, but are you sure the slave and master cylinder are working fully? Is it a mechanical or hydraulic (fluid) clutch?



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  • 33 Answers

Have you tried to use synthetic oil in it? I have synthetic in my '78 Honda four and it works good.

Posted on Feb 12, 2009


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How do i get the clutch out of a kawasaki vulcan 800 2003 model with out taking off motor

You dont have to remove the complete engine to replace the clutch !
All you do is remove the clutch cover with about 10 bolts securing it , might have to remove the foot peg and brake lever also !
Once cover is off then you will see the clutch assy , remove the end cover with about 6 bolts and then slide out the clutch plates KEEPING THEM IN ORDER !
Put your new clutch plates in a bowl of engine oil for an hour to soak , then check each metal plate for wear unless you are replacing them as well ! If you find they are a blue colour then lightly clean them with emery cloth ( abraisive paper for metal ) wipe clean and place new fiber coated plates in place of old worn ones sliding them back in order they came out ! Ive not got any torque settings but you can find them on the internet for the end cover and side cover , then replace the side cover etc !
Try the clutch , might have to adjust cable or if hydrolic then bleed by undoing the bleed nipple which is on the slave cylinder on the side of engine , undo it and pull lever in and hold it , tighten nipple , release lever and do this 2 or 3 times ! MAKE SURE THE CYLINDER ON THE CLUTCH LEVER IS FULL BEFORE YOU START !! If a cable then adjust off the adjustment on the hand lever leaving about 5mil slack , pull lever several times then re adjust cable till 3mil clearence on lever and try again ! Start engine and select 1st gear and carefully take for a ride changing gears , might have to adjust again but now should be ready to go and play !

Feb 20, 2015 | kawasaki Motorcycles

1 Answer

Clutch slipping 1999 Vulcan Classic 1500

Yes, he should have... The problem IS not enough "slack", "clearance", "free play" in the clutch itself once it gets warmed up.. make DOUBLE sure you have the correct fluid in the hydraulic system (if its wrong - it will overheat and expand and cause this very issue!!)..

THINK about whats happening.... when it gets warm, the "slack", "freeplay", and other "clearance" in the entire clutch system is being eliminated due to thermal expansion.. and then the slipping starts... Have the mechanic make DOUBLE SURE he has the metal plates and fiber plates stacked in the correct order and the correct amount of each... and NONE are warped!
good luck!

Sep 05, 2017 | kawasaki Motorcycles

2 Answers

My clutch won't engage 1997 Honda civic

Clutch plate and pressure plate seem to be too weak to pull the car. To test the clutch plate, park the car on flat surface. Pull the hand brake up, start the car, depress the foot brake pedal, depress the clutch pedal, put the car in 1st gear, press the gas pedal and leave the clutch pedal at once, while keeping the brake pedal depressed.
Follow one of the two following statements:
1. Engine does not shut down and remain start. (Clutch plate, pressure plate and clutch bearing defective - Replace all as a set)
2. Engine shuts down. (Clutch system is OK and does not require any repair).

Apr 06, 2013 | 1997 Honda Civic

1 Answer

My clutch goes to the floor, can't shift. Have replaced slave cylinder, master slave cylinder, and the entire fluid line, also have bled them, but it's as if I did nothing. still can't shift

Provided the mechanical portion of our clutch is good then you still have some air somewhere in the hydraulic system and it's often very hard to get out. One trick I use is to use my hand vacuum pump with a little cover I made to cover the fill hole on top of the master cylinder. I pump up about 15" of vacuum on the system and often that will pull out the few air bubbles submerged in the fluid that prevent the system from working. Once you get most of the air out usually the rest will work out if you press and release the clutch pedal several times. Sometimes it works very quickly, sometimes I've fought them for an hour or more to get back to a normal pedal. Of course if you have an actual mechancial problem inside the bellhousing with the pressure plate or disc then nothing you do on the outside will work until that is repaired.

Jul 01, 2010 | 1989 GMC Sierra

3 Answers

99 rodeo Clutch bearing pulls out

If this is a hydraulic clutch, ask your mechanic to change the master cylinder (slave cylinder). This could have a leak (which he/she should have found, and checked this). If not, the cable may be too loose, or is not hooked up correctly.

Please let me know if you need further assistance.


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Jun 02, 2010 | 1999 Isuzu Rodeo

1 Answer

My clutch disengages very inconsistently, sometimes working perfectly then for no apparent reason, not disengaging very well at all even though the clutch pedal is to the floor. I have replaced and bled...

This sounds outrages for the hydralics,price the clutch set at the auto parts store,then ask how much in labor cost to see what it actually cost,but yes the clutch is the most likely problem.

May 18, 2010 | 1996 Toyota 4Runner

1 Answer

The clutch is sticking to the floor board.Do I have to replace the entire clutch or perhaps just a part? FORD 1996 F250

as the clutch is 3 parts and you dont want to take the gearbox down every time to replace a bit,best replace the bearing/friction plate and pressure plate at same time(much cheaper too...less labour costs)

May 04, 2010 | 1996 Ford F250 Crew Cab

1 Answer

I need to tear down my transmission in a 1988 Chevrolet Cavalier Z24 2.8L i am fixing the clutch and i need diagrams on how to take it apart and put it back together

Below is process for removing and replacing the clutch assembly.
Hope this helps, good luck.


See Figures 1, 2 and 3

0900c1528003be16.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Fig. 1: Exploded view of the clutch disc and cover assembly
  1. Disconnect the negative battery cable.
  2. If equipped with a cable clutch (1982-84 vehicles), disconnect the cable at the clutch release lever and transaxle, as outlined earlier in this section.
  3. For 1985-94 vehicles remove the sound insulator from inside the vehicle. Disconnect the clutch master cylinder pushrod from the clutch pedal.

0900c1528003be17.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Fig. 2: Disconnect the clutch actuator (slave) cylinder line - 1995-96 vehicles
  1. Remove the transaxle, as outlined earlier in this section.
  2. Mark the pressure plate assembly and the flywheel so that they can be assembled in the same position. They were balanced as an assembly at the factory.
  3. Loosen the attaching bolts one turn at a time until spring tension is relieved.
  4. Support the pressure plate and remove the bolts. Remove the pressure plate and clutch disc. Do not disassemble the pressure plate assembly; replace it if defective.
  5. Inspect the flywheel, clutch disc, pressure plate, throwout bearing and the clutch fork and pivot shaft assembly for wear. Replace the parts as required. If the flywheel shows any signs of overheating, or if it is badly grooved or scored, it should be refaced or replaced.

0900c1528003be18.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Fig. 3: You must follow the specified sequence when tightening the pressure plate retaining bolts
To install:
  1. Clean the pressure plate and flywheel mating surfaces thoroughly.
  2. Position the clutch disc and pressure plate into the installed position, and support with a dummy shaft or clutch aligning tool, tool J 29074 or equivalent. The clutch plate is assembled with the damper springs offset toward the transaxle. One side of the factory supplied clutch disc is stamped "Flywheel Side".
  3. Install the pressure plate-to-flywheel bolts. Tighten them in the sequence shown in the accompanying figure, as follows:
    1. Tighten bolts 1,2,3, then 4,5,6 in the sequence shown to 12 ft. lbs. (16 Nm).
    2. Tighten bolts 1,2,3, then 4,5,6 in the sequence shown to 15-22 ft. lbs. (22-30 Nm) plus an additional 30° turn.
    3. Remove the clutch alignment tool.

  4. Lubricate the outside groove and the inside recess of the release bearing with high temperature grease. Wipe off any excess. Install the release bearing.
  5. Install the transaxle, as outlined earlier in this section.

WARNING When adjusting the cruise control switch, do NOT exert an upward force on the clutch pedal pad of more than 20 lbs. (89 N) or damage to the master cylinder pushrod retaining ring may result.

  1. For 1985-94 vehicles, attach the clutch master cylinder pushrod to the clutch pedal and secure with the retaining clip. If equipped with cruise control, check the switch adjustment at the clutch pedal bracket. Install the sound insulator.
  2. If equipped with a cable clutch, attach the clutch cable at the transaxle and clutch release lever. Check the clutch operation by lifting the clutch pedal up to allow the mechanism to adjust the cable length. Depress the pedal slowly a few times to set the pawl into mesh with the quandrant teeth.


All 1982-84 models have a self-adjusting clutch mechanism located on the clutch pedal, eliminating the need for periodic free play adjustments. The self-adjusting mechanism should be inspected periodically as follows:
  1. Depress the clutch pedal and look for the pawl on the self-adjusting mechanism to firmly engage the teeth on the ratchet.
  2. Release the clutch. The pawl should be lifted off of the teeth by the metal stop on the bracket.

On 1985 and later models, the hydraulic clutch system provides automatic clutch adjustment. No adjustment of clutch linkage or pedal position is required.

May 04, 2009 | Chevrolet Cavalier Cars & Trucks

1 Answer

Need to change my clutch plates

Lay her on the left side, with the fuel OFF!!! Remove the clutch cover plate, remove the small bolts (5 or 6) for the outer clutch cover. Pull that cover out, and start pulling out plates, one at a time. Make sure you got all of them, as they stagger from metal (or aluminum) to fiber.Lay them out as they came out of the machine. Soak the new fiber plates in a good oil for a while before installing. Also make sure the "tangs" that the clutch plate ears ride on aren't grooved from wear. It it is bad here, you can file them down, unless it's really destroyed, then the basket needs to be replaced.
Reassemble in reverse order.

Apr 08, 2009 | Cars & Trucks

1 Answer

How do i replace my clutch kit. i burned it out

ello mate,,first drain the oil out,remove the right side lower fairing,,then remove the wot looks like a large circular engine casing,then remove the bolts with springs holding the clutch plates in,,take off the cover then u will see the plates and metal lookin clutch plates,, now take out the clutch plates one at a time,,,ie take one out then place on the bench,take a metal plate out and place that on top of the 1st plate u took out,and so on,, when u have the new fibre plates,,replace back in the bike as u took the old ones out,,ie, new fibre plate 1st then put a metal friction plate back in from your bench,,then a new fibre plate and so on,,each time u replace the new plate ,chuck away the old one,,wen u have done that ,on the clutch plate cover look at the face of the cover u will see a small arrow head or a dot stamped on the face of it,, that dot should line up with a dot thats stamped on the housing where the clutch plates are,put the plate casing on so that the dots line up ,,put the springs and bolts back on and do them up tight,,then replace the engine casing,,,put your oil back in,,if u have a hydrolic clutch u will have to remove the 3 screws and the clutch piston b4 taking the casing off ,,,to read this it will sound complicated m8,, but wen u start the job itl be quite easy,, take your time tho,,any probs m8 ,shout and il anserw u,, ok,, cheers now

Mar 30, 2009 | 2007 Suzuki GSX-R 600

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