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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  • Contributor
  • 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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1 Answer

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

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Yamaha wr200 bike clutch fitment


take clutch case off , you then see the clutch basket and you need to remove the center plate with about 6 bolts , then remove the fiber coated plates along with metal plates .. then replace first a fiber coated plate followed by a metal plate then a fiber following this until all plates are in and a fiber plate is showing ! then replace the cover plate with 6 bolts , tighten all bolts then undo the center nut with the adjusting screw and back it off until there is slight free play on the clutch leaver as you pull it and then release! lock the nut up holding the screw and try ! soak fiber plates for an hour before installing also ! cheers

Dec 04, 2013 | Motorcycles

1 Answer

Transmission slipping in 2nd gear under hard acceleration


You need to replace the clutch plates. Once they start to slip you won't be able to readjust them with any success. Take a good look at both fiber clutch plates and the metal ones. You can replace just the fiber plates and it most likely won't slip anymore, but if you replace both fiber and metal plates it will last much longer. If you are on a budget and want to temporary repair it you can add washers to the clutch springs to add tension. Use spark plug washers, they fit perfect. I've done this on a couple of motorcycles with good results. But i do recommend replacing the clutch plates as i stated above.

Jan 22, 2012 | 1989 Yamaha FZR 1000

1 Answer

Need instructions on how to change my clutch on my 97 roadking


All you have to do is drain and pull the primary cover. Now, I can't remember whether the '97 clutch had the bolts that hold it together or the snap ring. If it has the six bolts holding the clutch spring in, simply take the bolts out and your clutch assembly comes apart. You can change the fiber plates and the spring plate in the middle. If your clutch is held together with a snap ring, you'll need a special tool to disassemble the clutch. You can replace the friction plates, steel plates and the spring plate without taking the entire clutch off the mainshaft with either clutch.

Good Luck
Steve

Jun 04, 2011 | Harley Davidson FLHR-FLHRI Road king...

1 Answer

HAVE A 1999 SPORTSTER 1200C PULL MY CLUTCH LEVER IN AT IDLE TO SHIFT TO FIRST GEAR AND HEAR IT CLUNK IS THIS NORMAL?


Well, the answer is yes and no. If you hear a clunk noise when shifting to first gear when the engine and transmission is cold, this is normal. Once the engine reaches normal operating temp, the answer is "NO", not normal.

In a cold engine, the oil is thick and even with the clutch pulled in, enough oil is between the plates to drive the mainshaft and cause the noise. Now. once the oil gets hot, it shouldn't do this. If it does, you need to adjust the clutch.

To adjust the clutch, find the cable adjuster in the middle of the clutch cable. Loosen the locknut and turn the adjuster inwards to get as much slack in the cable as possible.

Now, remove the derby cover, spring, and locknut at the clutch release mechanism on the outer primary cover. Inside the mechanism is a screw. Turn this screw as far as it will go clockwise but don't try to force it. Once it stops, turn the screw back clockwise 1/4 turn. Replace the "locknut", spring, and the derby cover over the release mechanism.

Now, go back to the cable adjuster and adjust it back outwards until you get about an 1/8" of freeplay. Squeeze the clutch a few times and check the freeplay again. Lock the lock nut and replace the rubber boot over the adjuster.

Good Luck
Steve

Jan 13, 2011 | 2000 Harley Davidson XL 1200 C Sportster...

1 Answer

How does the clutch cable release work under the clutch release cover?


The clutch cable hooks to the screw assembly. The assembly is bolted to the case. When the clutch lever is pulled in, the center part of the assembly, ( a giant screw mechanism ), pushes on the clutch rod which then pushes on the outer clutch pressure plate to separate the clutch plates. The clutch springs supply the pressure to push the clutch lever outward thus engaging the clutch to move forward. I hope this answers your question. Please rate my answer. Thanks.

A diagram of the entire bike and engine can be found at www.babbittsonline.com/pages/parts/viewbybrand/default.aspx


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Aug 06, 2010 | 1984 Suzuki Gs 550 L

2 Answers

'95 Yamaha YZ 125 clutch - stays in gear when clutch is pulled in


the plates will stick to each other because of oil
check the clutch lever at the motor and make sure it is moving the arm that pushes the pressure plate and make sure it is moving

Apr 15, 2009 | 2003 Yamaha YZ 125

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

1 Answer

Clutch


where it doesnt fully engage but I am having the opposite problem where I can not get my clutch to disengage. I have the top cable adjuster-adjusted so there is about a nickels (few mm) worth of play where i can pull the clutch lever that much before the cable really starts pulling. With it on the stand when i start it and put it in gear the wheel spins (enough that it is hard to stop the wheel and if i do the bike stalls) even with the clutch lever pulled all the way in and when riding it, the clutch doesnt actually seem to engage until the lever is almost all the way out. I adjusted the cable adjuster and unscrewed it as far as it can unscrew which was considerably further out then it is with the nickels worth of play and it changed nothing aside from the tightness of the lever/cable. On the stand the wheel still spins and stalls if i put enough force on it to stop the wheel and when riding the clutch still seems to engage and the same point (where the lever is almost all the way out). I think when I am on it and put it in gear, it doesnt stall becuase i keep the Rs up and my weight keeps the back tire from turning and slips the clutch?? Any comments, ideas, advice, etc. would be greatly appreciated. Thanks in advance. ,well , the most obvious is a worn out clutch..BUT it can also be from the plates sticking together, or the springs are beyond their service limit. you can check and change all this at once.... 1) drain the oil 2) take off the clutch cover 3) loosen the screws that hold the pressure plate 4) check the springs (they should be a specific length , over time the length decreases) 5) take out pressure plate 6) check every plate , you can check thickness with a good caliper.( if the pads on the thick discs look worn or are not there the clutch is worn and you need a new set of plates) if they discs are still in good condition try cleaning them with a solvent like alcohol etc...but be carefull you do not use a aggressive solvent as the pads are made from cork and some solvents will damage the cork . If you change the pads the best thing to do is change the metal and the friction pads aswell as the springs. there's a trick to use a clutch that's worn down alot and that is to add another metal plate to the outside so your total stack height becomes higher , however this will only help you 1 or 2 heats after that the clutch is toast either way. hope thats FIXYA.,,,

Nov 10, 2008 | 2001 KTM EXC 125

1 Answer

Slipping clutch


clutch basketYou will need the fibre clutch plates and I would be replacing the clutch springs because the 400 had weeker springs than the 450 (04YM). Also check if the metal plates are blue this is a sign they are bernt and they may need replacing if it has been slipping for a period of time. Use 10w 40 oil. Motul or Motoex oil they are good and go genuine some non genuine plates can swell and cause drag. Sometimes the basket may have small wear marks on the fingers. If it has you can clean them up with a file but dont take to much off. The only other reason you would replace the basket is if the damper rubbers between the basket and big gear are worn.Try and move the gear and hold the basket, if the gear moves the dampers are worn and need replacing, I think you can get the dampers seperate. If you go to a good Gas Gas dealer you wont get riped off, I would take your plates in and ask for the mechanic for advice and not the parts person.,,,

Nov 10, 2008 | 2003 Gas Gas EC 400 FSE

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