Is the clutch in my Z400 going bad??

iqraceworks · 01-30-2012, 01:12 PM

I have an 03' Z400 with mild mods (DRZ base gasket, full intake, full exaust). Other than that it's all stock. It mostly trail ride...and rarely abuse the clutch and slip it a lot.

I've started to notice that the clutch is starting to become kind of "notchy" when I let out on it...it's not smooth like it used to be. Sometimes as I let it out it will just grab all of a sudden. The cable is in good shape, and I just recently lubed it.

Also, I'm having to let the clutch lever almost all the way out before it starts to grab...but I have the cable screwed into the lever all the way...and there is no more adjustment. Are my friction plates in the clutch just getting so thin that it's go to travel that far before it locks up?

It seems to hold fine...but I'm wondering if these are the sings that I should replace it soon before it completely dies on me out on the trail.

TRMN8TR · 01-30-2012, 01:34 PM

If its grabbing fine once its engaged, but having problems engaging and feels "notchy" check your clutch basket inner and outer. They most likely have grooves worn in them that are hanging up the plates. A permanent fix is to replace them, the poor mans fix is to file them down smooth again. (Easy job, they are aluminum.)

You can get away with filing once or twice, but the more you do it the faster they wear. Once you file them the gap is bigger and allows the plates to "slam" against the baskets and causes them to wear faster. Eventually you'll have to replace them.

CFM-Z440 · 01-30-2012, 01:45 PM

Mine has always acted similar to that when it's cold. The clutch plates would chatter when I would engage the clutch hard to jump it off of my trailer not that long after starting it. Once everything was warmed up to operational temp, it wouldn't do it. I noticed it way more with the stock plates than I do now with the barnett plates. Is your clutch issue sensitive to temp?

iqraceworks · 01-30-2012, 01:47 PM

Quote:

Originally Posted by CFM-Z440

Mine has always acted similar to that when it's cold. The clutch plates would chatter when I would engage the clutch hard to jump it off of my trailer not that long after starting it. Once everything was warmed up to operational temp, it wouldn't do it. I noticed it way more with the stock plates than I do now with the barnett plates. Is your clutch issue sensitive to temp?

It doesn't seem too sensitive to temp. It seems to work the same regardless if it's hold, or hot after riding for a while. Shouldn't I be able to adjust my cable in more so that the clutch is locking up sooner...and not as the lever is almost all the way out?

zookie400 · 01-30-2012, 03:11 PM

what kind of oil are you running?

TuckerHardRide · 01-30-2012, 03:52 PM

Quote:

Originally Posted by zookie400

what kind of oil are you running?

+1 I think i have a thread about this issue.

iqraceworks · 01-30-2012, 07:41 PM

I'm running Rotella T 15w-40. Been running it in my Z400 and YFZ450 for a few years, seems to work really well. Bad choice?

TRMN8TR · 01-30-2012, 08:14 PM

Just was searching about rotella last night. Seems lots of people on the forum are using it with good results, and now I will be too. I think you just need to pop the clutch cover off and inspect. You're quad is 9 years old and likely the friction plates and baskets are worn. Measure the friction plates at several places. They should be 2.9-3 mm and the service limit is 2.6. The drive plates should be 2.92-3.08 mm and their service limit is also 2.6. And look for the grooves on the baskets like I said earlier.

iqraceworks · 01-30-2012, 08:19 PM

Yep...I think you are right. I just need to pull the clutch cover and check it all out!

TRMN8TR · 01-30-2012, 08:30 PM

Ya its like a $5 gasket and some cheap rotella. Check the obvious signs of wear and measure what you can. If everything is in spec and its still acting up then start looking for other things.

spize909 · 01-30-2012, 08:35 PM

If you're gentle and the stars all align............you can re-use the side cover gasket.
I would also agree that an inspection is probably in order.

zookie400 · 01-31-2012, 12:32 AM

Quote:

Originally Posted by spize909

If you're gentle and the stars all align............you can re-use the side cover gasket.
I would also agree that an inspection is probably in order.

haha thats funny, stars only align for me when i am working on someone elses machine.

conventional rotella is fine for oil. synthetic oilcan do funy things with the clutches.

kapt1eye · 01-31-2012, 01:18 AM

My buddy had exactlly the same problem...a new basket resolved it.
He went with OEM...I would go with a Billetproof, so you never have to do it again.

TuckerHardRide · 01-31-2012, 06:48 AM

Quote:

Originally Posted by TRMN8TR

Ya its like a $5 gasket and some cheap rotella. Check the obvious signs of wear and measure what you can. If everything is in spec and its still acting up then start looking for other things.

I wanna buy the gasket where your getting it. The last time I bought one it was $14!

TRMN8TR · 01-31-2012, 07:05 AM

Quote:

Originally Posted by TuckerHardRide

I wanna buy the gasket where your getting it. The last time I bought one it was $14!

Haha well that's not the point...the point was tear it open already and inspect it, not gonna break the bank.

Here, $4.99 at auto zone. Trace it out and make your own.

Fel-Pro/10 x 26 x 1/32 in. rubber and fiber gasket material sheet (3157) | Gasket Material | AutoZone.com

01-30-2012, 01:12 PM	#1 (permalink)
iqraceworks :::Ozark 250 rider::: Join Date: Mar 2008 Posts: 276	Is the clutch in my Z400 going bad?? I have an 03' Z400 with mild mods (DRZ base gasket, full intake, full exaust). Other than that it's all stock. It mostly trail ride...and rarely abuse the clutch and slip it a lot. I've started to notice that the clutch is starting to become kind of "notchy" when I let out on it...it's not smooth like it used to be. Sometimes as I let it out it will just grab all of a sudden. The cable is in good shape, and I just recently lubed it. Also, I'm having to let the clutch lever almost all the way out before it starts to grab...but I have the cable screwed into the lever all the way...and there is no more adjustment. Are my friction plates in the clutch just getting so thin that it's go to travel that far before it locks up? It seems to hold fine...but I'm wondering if these are the sings that I should replace it soon before it completely dies on me out on the trail. __________________ 2003 Z400, Full Trinity Stage IV Exhaust, Custom Intake w/no lid, DRZ base gasket, 13t front sprocket, 06' Z400 front shocks, ProTaper bars, Trailtech mounts, Jardine Nerf Bars, Tusk Comp Heal Guards Primary Drive X-Ring Chain, Primary Drive 42t Rear Sprocket

01-30-2012, 01:34 PM	#2 (permalink)
TRMN8TR :::Z-250 Rider::: Join Date: Nov 2011 Location: Location: Location: Posts: 402	If its grabbing fine once its engaged, but having problems engaging and feels "notchy" check your clutch basket inner and outer. They most likely have grooves worn in them that are hanging up the plates. A permanent fix is to replace them, the poor mans fix is to file them down smooth again. (Easy job, they are aluminum.) You can get away with filing once or twice, but the more you do it the faster they wear. Once you file them the gap is bigger and allows the plates to "slam" against the baskets and causes them to wear faster. Eventually you'll have to replace them. __________________ 2006 z400. It has things and stuff.

01-30-2012, 01:45 PM	#3 (permalink)
CFM-Z440 Super Moderator Join Date: Sep 2006 Location: Southern Minnesota Posts: 6,437	Mine has always acted similar to that when it's cold. The clutch plates would chatter when I would engage the clutch hard to jump it off of my trailer not that long after starting it. Once everything was warmed up to operational temp, it wouldn't do it. I noticed it way more with the stock plates than I do now with the barnett plates. Is your clutch issue sensitive to temp? __________________ 03 LT-Z 470 Max Power 12.5:1 94mm Piston, Hot Rods +5 Stroker Crank, Web Cams 539 (+6) IN / 539 EX, with Hot Cams sprockets, Ferrea +1 Valves, LTZ/DRZ springs (IN)DRZ springs (EX), DRZ Manual Decomp. Ported head, FCR 41 with Noss adaptor, Home made intake, Modified HMF Full System, Home made header, Trailtech flywheel, Dyna Programable 54hp 36ft lbs

01-30-2012, 07:41 PM	#7 (permalink)
iqraceworks :::Ozark 250 rider::: Join Date: Mar 2008 Posts: 276	I'm running Rotella T 15w-40. Been running it in my Z400 and YFZ450 for a few years, seems to work really well. Bad choice? __________________ 2003 Z400, Full Trinity Stage IV Exhaust, Custom Intake w/no lid, DRZ base gasket, 13t front sprocket, 06' Z400 front shocks, ProTaper bars, Trailtech mounts, Jardine Nerf Bars, Tusk Comp Heal Guards Primary Drive X-Ring Chain, Primary Drive 42t Rear Sprocket

01-30-2012, 08:14 PM	#8 (permalink)
TRMN8TR :::Z-250 Rider::: Join Date: Nov 2011 Location: Location: Location: Posts: 402	Just was searching about rotella last night. Seems lots of people on the forum are using it with good results, and now I will be too. I think you just need to pop the clutch cover off and inspect. You're quad is 9 years old and likely the friction plates and baskets are worn. Measure the friction plates at several places. They should be 2.9-3 mm and the service limit is 2.6. The drive plates should be 2.92-3.08 mm and their service limit is also 2.6. And look for the grooves on the baskets like I said earlier. __________________ 2006 z400. It has things and stuff.

01-30-2012, 03:11 PM	#5 (permalink)
zookie400 :::Post Whore::: Join Date: Aug 2007 Location: Connecticut Posts: 2,675	what kind of oil are you running?

01-30-2012, 08:19 PM	#9 (permalink)
iqraceworks :::Ozark 250 rider::: Join Date: Mar 2008 Posts: 276	Yep...I think you are right. I just need to pull the clutch cover and check it all out! __________________ 2003 Z400, Full Trinity Stage IV Exhaust, Custom Intake w/no lid, DRZ base gasket, 13t front sprocket, 06' Z400 front shocks, ProTaper bars, Trailtech mounts, Jardine Nerf Bars, Tusk Comp Heal Guards Primary Drive X-Ring Chain, Primary Drive 42t Rear Sprocket

01-30-2012, 08:30 PM	#10 (permalink)
TRMN8TR :::Z-250 Rider::: Join Date: Nov 2011 Location: Location: Location: Posts: 402	Ya its like a $5 gasket and some cheap rotella. Check the obvious signs of wear and measure what you can. If everything is in spec and its still acting up then start looking for other things. __________________ 2006 z400. It has things and stuff.

01-30-2012, 08:35 PM	#11 (permalink)
spize909 :::Get a life! You're over 5000 posts::: Join Date: Oct 2008 Location: Southern California Posts: 5,245	If you're gentle and the stars all align............you can re-use the side cover gasket. I would also agree that an inspection is probably in order. __________________ 2005 Z-400 Mine *January* *2011 QOTM* 2004 Z-400 Brad'Z *October 2011 QOTM* http://www.suzukicentral.com/forums/...tm-winner.html 2004 Z-400 Wife's 1996 Sandsprite IV (sandrail) MINE Sponsors: Coors Light.............I sponsor them! *Life is tough...........it's tougher if you're stupid.*

01-31-2012, 01:18 AM	#13 (permalink)
kapt1eye :::Mini LT80 Rider::: Join Date: Jan 2012 Location: Vernon,BC,Canada Posts: 152	My buddy had exactlly the same problem...a new basket resolved it. He went with OEM...I would go with a Billetproof, so you never have to do it again.

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