Hi John Talley here with Partzilla.com.
Today we're going to be working on our 2007 Honda Trx400Ex.
In particular we're going to be looking at the clutch plate system on it.
One of the first things we needs to do is drain the oil out of the machine.
If you need help doing this reference one of our videos that shows you how to do an
oil service and it will cover all the aspects that you need to look at.
Alright, once the oil is out of the machine we need to go ahead and remove our brake lever,
our clutch cable, our reverse cable, our send and return lines for the oil tank itself and
then all these 8mm bolts that hold on the side cover.
I'm going to use an impact wrench to take off those bolts but you do not want to use
that to reinstall them because you run the risk of stripping out the threads and you
dang sure don't want to do that.
So let's get started.
We will begin my removing the brake pedal.
To accomplish this you need to pull out the copper pin that's holding the pivot pin in
place.
Then remove the allen bolt on the front of the brake pedal.
With a little bit of wiggling you should be able to pull the entire brake pedal off the
frame taking the spring with it.
Next up is the reverse cable.
It's held in place by a 10mm pinch bolt.
Remove the nut and washer on the cable holder and it should easily come right off.
Then remove the clutch cable.
What you need to do here is loosen up the bolt on top where you have more length to
adjust the cable so you can remove it from its hook.
Just like that.
Then grabbing it from the top with a pair of pliers you can get it to slide all the
way out and release.
Next you want to remove the oil pipes.
Keep in mind that you'll have some oil draining out from these so be sure to have a pan underneath
to catch it.
Also want to be careful not to lose the o-rings that are inside.
Now you can go ahead and take out all those 8mm bolts that were holding the cover on.
You want to keep up with what bolts go where because they're all different lengths.
I usually start with this one and lay them all out on a table as I go around, knowing
that this is my first one so I can get them back in the right place when I'm finished.
Now you'll need to use a flat head screwdriver up in this area here from behind to pry the
cover off.
It should pop right off like that.
And then when you come around to the other side, pry it from here to get it to come off
evenly.
Now you should be able to guide the cover right off revealing the clutch pack.
The clutch pressure plate is removed by loosening the bolts in a crisscross pattern.
You have to do it this way because there are springs and we want to keep an even tension
as we're removing it.
Now you can remove the pressure plate and you'll see that you'll have one fiber disk
that is off one location in orientation.
You want to make sure you put it back together this way.
The next disk is a metal disk.
This pattern is continued through the rest of the pack leaving a total of seven fiber
disks with six metal disks.
Now is a good time to take a moment and inspect the clutch drum for any wear marks that will
show up on these outer edges of the drum and the basket.
If they are worn you will see little ridges like steps along these areas.
Now let's take a look at our clutch disks and plates.
The service limit is 2.69mm in thickness for the fiber disks.
If it falls below that they will start slipping and you will lose performance.
When inspecting your metal clutch plates you're looking for a blueish tint that indicates
that it has been overheated.
These plates are clearly in need of replacing.
So what we're going to do next is fill a tray with some Honda GN4 oil and submerge all of
our fiber plates and make sure they all get covered in oil completely.
While we're waiting for the oil to be absorbed into our fiber plates now would be a good
time to start scraping off all that old gasket material.
Make sure to remove the two dowel pins before you get started, which you can find here and
here.
All you need is a razor blade but be very careful when you start peeling the gasket
back.
What you don't want to do is to gouge the casing which can cause it to leak later on.
You'll also need to remove the gasket remnants on the cover.
They should be relatively smooth and clean when you are finished.
To insert the new clutch disks, begin with a fiber disk first followed by a metal plate
and then repeat this pattern until the very last fiber disk.
Remember you need to be off by one tooth on that last fiber disk.
Then you'll have to replace the pressure plate, tightening the bolts in the same crisscross
pattern as you did when it was removed.
Next you want to put in your dowel pins which will align your gasket and put the cover back
on while turning the clutch lifter arm to engage the spindle groove which you can see
here.
Align it all up, push on the cover and replace all the cover bolts followed by the oil lines,
the reverse cable, and the clutch cable.
You'll need to adjust the tension in these cables before the project is complete and
for that you can refer to our clutch lever adjustment video.
When you get to the point of replacing your brake pedal, be sure to clean it up.
I used a wire brush.
You want to cover the pivot point with grease before putting it back on the machine.
Alright guys, with that buttoned up all you need to do now is refill your oil system.
If you would, reference our Oil Service video it'll show you exactly how to get it refilled
and check the level appropriately.
The second thing is to go ahead and adjust your clutch lever, which we also have a clutch
lever video.
Shows you exactly how to do it step by step.
Listen if you need any of the products or parts that we used to do this come see us
at Partzilla.com if you have any questions or comments just leave them below and I'll
get back to you on it.
Listen thanks for watching and we'll see you next time.