Topic: Clutch/Transmission issues when hot

[tsflstb]

I've got my 400F back on the road after some major transmission problems.  Everything seems to work fine while running around the block.  Bike shifts fine, clutch takeup is normal, etc...  I took my first longer ride this afternoon and after about 30 minutes, the clutch started acting up.

It seemed like it wasn't disengaging all the way.  I'd pull to a stop in 1st and pull in the clutch and I'd hear and feel gears thumping against each other.  The bike wanted to creep forward a little.  Also, it would just die when I shifted from neutral to 1st when leaving a stoplight.  Made me look like a real duma$$ a couple of times. 

Anyway, I readjusted the clutch cable and also the locknut on the little lever under the cover per factory specs thinking that would cure it, but a second ride gave me the same results.  The clutch is brand new (plates and springs).  The transmission is used but in good shape...dogs and shift forks appeared to be good.

Like I said, no problems until the bike gets good and warm.  Should I keep messing with the clutch adjustment or is there something else wrong?

[tsflstb]

Just diid another longer ride today, and I ended up adjusting the clutch arm quite a bit tighter than the factory spec.  Basically I just tightened the locknut to the point I felt resistance and left it there instead of backing it off 1/4 to 1/2 turn.  It seems to be working OK now and I don't feel it slipping at all.  This is the first time I've started with a brand new clutch, so I'm thinking it has to wear in a little?  It's got about 75-100 miles on it now, so hopefully it will stay in adjustment longer.  Anyway, maybe this will help somebody else later on.

[Jonesy]

Not to familiar with the 400F clutch, but did you soak the clutch plates before installation? The plates will soak up oil and swell a bit. If you assembled it dry you will likely have to keep playing the ride/adjust/ride/adjust game until you've done enough riding to fully oil the plates.

[chung]

It sounds like the clutch Adj is a bit tight. If the bike creeps at rest in gear or hammers into gear comming from N, then back it off a touch. There is no absolute number for the Adj, It's a Zen thing. I set the slack in the cable so that I can pull the lever a "fat  fuzz"  before it disengages the clutch. (20mm+-) This helps with fat gloves as well. A little extra slop in the cable is a good thing.
I miss my bikes
I guess I'll piddle with a few houses untill I can recover from the $$$ loss. You can actually get paid pretty well for doing someone elese's work for them. LOLLOL

[tsflstb]

Not to familiar with the 400F clutch, but did you soak the clutch plates before installation? The plates will soak up oil and swell a bit. If you assembled it dry you will likely have to keep playing the ride/adjust/ride/adjust game until you've done enough riding to fully oil the plates.

Oops. 

I didn't soak them.  That would pretty much explain it.  Thanks.

[chung]

oops, my drunkass got it backwards