86 WR 400 clutch

whoa thats alot...4-5mm is book spec.

way too much

Yep, 3-4mm at the crank case lever is plenty.
You need to adjust at the clutch pressure plate.

I have a new cable on the bike, When I put it on, the lever adjustment was all the way out. I adjusted the clutch with adjustment at the center of the clutch. I got it adjusted so the lever adjustment is all the way in. I took the cable off and it has the 15mm play. If I get that down to 5mm I doubt I will be able to get the cable on. I will have to tinker with it this weekend.
Maybe the cable is wrong?

Thanks for all the responses. I've been sick so just getting back to this thread.

Getting the cable on often I have screwed the adjuster in pretty much as far as it goes, turn the lock ring on the adjuster at the lever so the slot is forward, put the cable sheath end at the slot, pull in the lever, let the lever out while pulling on the cable sheath which will allow it to come out enough to get it in the pocket at the end of the adjuster thing. Then adjust as needed. Aftermaket lever assemblies sold by genuine husky dealers telling me why pay more for stock have not worked out for me. The adjuster was not as long and the distance from the pocket for the cable end to where the threads for the adjuster start was less. The lever at the engine should be pretty close to a right angle to the cable inner wires.

uh....sometimes even with proper play at actuator arm there can be improper adjustment of pushrod. meaning too long and will not allow pressure plate to snug up to clutch pack in the basket and replicates slipping/worn plates. Check that as well. Have also seen this go unchecked and then "groove wear" of the pressure plate so it wears so much "meat" off contact area of pressure plate that it can never close the gap as it should even when properly set.

Just sayin

Joe

The pressure plate looked good when I had it apart. Clutch pack measured good too. My adjuster rod at the clutch is about flush with the lock nut. Not sure if it's worn too much.

Dale

Pulled mine apart. free play adjustment wrong,reset, checked spring height-4.4mm on tow, 4.1-4-25 on three. Added washers to preload, rode it, still slips. Fiber plates measure about 3mm. Ordering a new clutch set