• Husqvarna Motorcycles Made In Sweden - About 1988 and older

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    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

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84 wr400 clutch cover re-assembly

tonyvisone

tonyvisone

Husqvarna
AA Class
hey guys,

my father bought this bike new and im trying to get it going again

the clutch didnt work, i pulled it apart and all the plates came out as one piece. i re-assembled it with new plates and a new push rod because that was squashed.

now i am trying to just put the clutch cover back on. when i do its a pain because of that tooth and sping on the kickstart assembly. i have to get the cover close and then blindly push the tooth in with a flathead. although i can get this to work, and bolt the cover down, when i push the kickstart down by hand it makes a funky spring noise and doesnt return correctly.

any help?

also, a service manual would be awesome, and can i put 10w-40 honda motorcycle oil in? is it supposed to have 20w-50?
 
You set the kickstart bits up in the clutch case with pre load on the bench and then you slip the case on.
The only trouble I have ever had is getting the waterpump drive dog to match.
There's a service manual on this site somewhere. [Vintage Tec Ref section.]
The 85 and 86 engines are much the same as yours and the manuals will be usable.
The oil is supposed to be SAE 20 which you can't buy anymore so most people use SAE 30 which is Briggs N Stratton engine oil.
I use it and it works fine.
Next time your clutch sticks just poke a screwdriver in the oil filler hole and pop the plates apart.
 
thanks

so how much preload should i have? i imagine i need to get this right on... and how do i hold it there? with the kickstart shaft?

can i just asseble it all with no preload and then use pliers or something to preload it and then put the kickshaft on?

and would the 10w-40 work? i already have a few gallons of it, and dont have any sae 20 or 30.
 
you should never pull the kickstart assembly apart, fatal mistake (unless something is broken). There is a good assembly description in my restoration thread by a couple of guys i think. for oil, Im using Belray gear saver 80 / 90 light oil and its working great. Smoothest cable clutch ive used in ages... KTM hydraulics sure spoil your clutch hand.... The sticking clutch is a std feature i think.. even having fully stripped, cleaned and light wet dried my plates they tend to stick on each cold start, ive learnt not to point it at anything expensive when i bang it into gear! Ive even got a fergie tractor thats the bloody same... nearly put that in the pool because the clutch stuck at a critical manoeuvre!! The Huskies can be a bit agricultural but once on the move they do all the important stuff well. hope the bike gets underway soon, you will have a lot of fun with it.
 
awesome video. wish it came up on google at first to save me and others time. got the bike together and rode it twice. ran great. just a few minor tweakings needed- rear brakes, clutch cable, lights, and front exhaust header spring.


suprize- thanks for the advice. my clutch is working great now. although my adjustment is all the way out and just tight enough. it also doesnt engage till the end of the levers action, and i sometimes need to push it out a bit. bad cable? i shot white lithium grease down it a few days ago which may have been a mistake. i put about 1.75 qts of the honda 10w-40 oil in. is there any sort of fill meter?
 
yep. check my rebuild thread, there is a level description in there and a note on how to adjust the clutch at the clutch push rod to reset your lever play. Sounds like you need to wind it in a turn or so at the clutch untill there is a slight resitance (its beggining to push on the plates)and back it off a tad so there is free play. The tech reference may have a description. Back all your cable adjusters right off first. This should give you a mid lever release point and if it drags, wind out t he clutch lever adjuster a tad. enjoy
 
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