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Old 02-17-2013, 11:05 AM   #5521
MartiniUp
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The clutch thing does make a difference, thanks for the pics Doc. I wonder why Honda did that.
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Old 02-17-2013, 12:47 PM   #5522
DrLewall
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Quote:
Originally Posted by RideFreak View Post
The plates in the incorrect orientation shouldn't keep the clutch from working, it's not optimal though.
this is true..although who ever had this motor before me, installed the plates wrong, the clutch did work..I put abt 8,000 miles on that motor with the clutch like that, BUT, every now and then, the clutch would chatter and grab, not all the time mind you, maybe once or twice a month, if that..it worked okay and I made do. It was hard to find neutral tho. I always had to fight with it to get into neutral with the motor running in idle. Was easier to stop the motor and find neutral.

So one day I fired it up. The clutch chattered and grabbed as I let the lever out and it was almost to the point of launching me as I let the lever out some, it was in severe grab mode and didn't feel right.

So I wanted to see what was going on in there and I removed the cover, and there it was, it jumped out at me right away. All this time I had been running it with the plates (the last plate) installed wrong. Super easy fix, and I did fix it.

Now I can find neutral in idle, SUPER EASY!!! The chatter and grab'n are gone The XR400 seems like it even shifts easier now.

The lesson I learned here, new to me motors, need to have the clutch looked at just incase they are not put together right, at a minimum.

After checking your clutch and you still have shifting issues, then I would suspect some other mechanical snafu.
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Old 02-17-2013, 03:05 PM   #5523
tbarstow
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Quote:
Originally Posted by MartiniUp View Post
The clutch thing does make a difference, thanks for the pics Doc. I wonder why Honda did that.
Yes it does. I fixed mine last night, then spent all day riding out here in the desert. Worlds of difference.

Now if I could just get some decent wide ratio gearing......
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Old 02-17-2013, 03:44 PM   #5524
Clem Kevin
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Hmmm, you guys have me wondering. I've had my XR400 for six years and still have a bitch of a time getting it into neutral, never opened the clutch once.
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Old 02-17-2013, 04:12 PM   #5525
aaron2a
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I'm checking mine tomorrow... I'm putting a new tank on and cleaning my carb also... Tank is cracked and carb keeps sticking.
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Old 02-17-2013, 05:00 PM   #5526
Ed@Ford
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Now if I could just get some decent wide ratio gearing......
My wish since 1997!!
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Old 02-17-2013, 06:42 PM   #5527
RideFreak
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If the clutch plates are oriented incorrectly, it's not going to be as good as it could be if installed correctly but it won't cause the transmission to jump down a gear or jump out of gear. DrLewall's pic above showing the incorrect placement is how clutches have been made for years, all the fiber tabs are in a line, many are still that way. If Aaron's description is correct, the 5th gear slippage could easily be the problem DrLewall pointed out but the jumping up or down a gear unfortunately is another problem. A properly working modern dirtbike transmission (which includes the XR4) doesn't require the clutch at all to shift correctly while moving.
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Old 02-17-2013, 07:12 PM   #5528
DrLewall
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Quote:
Originally Posted by tbarstow View Post
Yes it does. I fixed mine last night, then spent all day riding out here in the desert. Worlds of difference.

Now if I could just get some decent wide ratio gearing......
so did you find your plates installed wrong?

Quote:
Originally Posted by Clem Kevin View Post
Hmmm, you guys have me wondering. I've had my XR400 for six years and still have a bitch of a time getting it into neutral, never opened the clutch once.
Quote:
Originally Posted by aaron2a View Post
I'm checking mine tomorrow...
would be curious to know what you guys find also..keep us posted!
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Old 02-17-2013, 10:58 PM   #5529
tbarstow
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Originally Posted by DrLewall View Post
so did you find your plates installed wrong?
Yep. Good thing I only have 2 rides on the clutch since I replaced the plates and didn't put the last one in the correct orientation.
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Old 02-18-2013, 12:13 AM   #5530
Clem Kevin
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Quote:
Originally Posted by DrLewall View Post
would be curious to know what you guys find also..keep us posted!
It'll be a few weeks before I do, currently tearing down a yz250f to use for supermoto.
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Old 02-18-2013, 04:42 PM   #5531
aaron2a
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Not the problem. They are installed correctly.
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Old 02-18-2013, 05:11 PM   #5532
DrLewall
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Not the problem. They are installed correctly.
bummer!

then most likely you have a mechanical gremlin pesterin you..good luck

but at least your clutch is assembled correctly..and most likely, your clutch plates would mic out okay too..they do wear but it takes along time for them to do so, years in fact!
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Old 02-18-2013, 05:24 PM   #5533
aaron2a
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We'll it is 15 years old... No clutch work that I know of... Might just need new clutch plates?
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Old 02-19-2013, 02:56 AM   #5534
cirell
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hid light

I know its already on here somewhere but can some one tell me if the stock stator will run a 55watt HID light? Or would I need to upgrade to a bigger stator.
Thanks
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Old 02-19-2013, 05:01 AM   #5535
DrLewall
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Originally Posted by cirell View Post
I know its already on here somewhere but can some one tell me if the stock stator will run a 55watt HID light? Or would I need to upgrade to a bigger stator.
Thanks
it will..but remember, you're gettin close to the limit and if you have "other" items (brake lite, turn sigs, GPS, clock, Air conditioning, DVD player etc )that require some juice, you could be SOL..
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