86 400 XC Clutch adjustment

[husky jim]

Data Sheet says 2.05mm. Most people run between 1.8 - 2.0mm
1.8mm should help on starting and kick back

Here some info you might like to have

 

[Quimo]

Perfect, thank you! I was even able to save these into my phone with the click of a button for future reference. I acquired a dial indicator and have an old spark plug and will give making one of those a try.

Can I use anything that fits well (like the tip of an appropriately sized punch) for the purposes of keeping the holes lined up while I turn stator and flywheel? Or, is there a special tool I should be acquiring?

 

[ruwfo]

The 400 is known for running backwards too, mine would do it at least once a riding season, but never kicked back

 

[husky jim]

Perfect, thank you! I was even able to save these into my phone with the click of a button for future reference. I acquired a dial indicator and have an old spark plug and will give making one of those a try.

Can I use anything that fits well (like the tip of an appropriately sized punch) for the purposes of keeping the holes lined up while I turn stator and flywheel? Or, is there a special tool I should be acquiring?

I use a drill bit that has a snug fit.

 

[Quimo]

I made a dial with an old spark plug and the reading came out to a healthy 1.87 mm BTDC. I decided to go through the motions of setting the timing to 1.8 since the original problem started because one of the bolts holding the backing plate on came loose (i.e., adding loctite to the bolts was a good idea).

Set the timing to “exactly” 1.8 BTDC, put everything back together, and voila! Starts up first kick without any kick back and idles like a dream.

Clutch was still slipping when I tried for a test run even with what I think is the right amount of play at lever and arm. Since going through the motions with the timing worked like a charm, I will do the same with the clutch and see where we end up.

 

[husky jim]

Clutch was still slipping when I tried for a test run even with what I think is the right amount of play at lever and arm. Since going through the motions with the timing worked like a charm, I will do the same with the clutch and see where we end up.[/quote]


The clutch pack adjustment is important. When adjusting I always error to the side of more play in the rod. If you have too much play it may drag a little with the clutch is pulled in, but won't slip!

 

[Quimo]

Opted for a new clutch cable (old one was pretty chewed up) and gave the lever more play and everything is running fine. She’s not a pretty bike, but even against a new 450 it is a blast! Have to finish putting plastics on and get the front fork worked over. View attachment 103713View attachment 103714 View attachment 103713 View attachment 103714

 

[Quimo]

What’s a good starting point for setting rear shock sag on these bikes?

 

[steadydirt]

Back on the clutch; over time the pressure plate wears. A little bit more on the outside edge than on the inside edge. The face develops a slight taper. You can cut a small groove on the inside edge of the pressure plate to mitigate this wear and keep the first clutch plate in more even contact.

 

[steadydirt]

Opted for a new clutch cable
On the forks; make sure the tapered aluminum rings are in good shape, they wear quickly and can stick inside the tube and scare the sht out of you as the fork leg will lock up for a second.

 

[Ventabular]

Th

In my opinion , before you try kickstarting your bike again you should check out how your kick starter is set up , especially since you say that it is kicking back . Did you remove the kickstarter to remoce the clutch cover ? Or maybe a previous owner did . What some owners tend to do is to rotate the kickstarter to try and get a more complete kick to help it start easier but what that does is remove the play in the kick start mechanism to the point that if it kicks back , the pawl that contacts the starting gear under the clutch cover either can’t or doesn’t have enough time to release . This can result in some expensive broken parts that could include the left (clutch side ) center case . I believe there is a post about ‘timing’ of the kickstarter that you may want to find and watch . You should also check that all your grounds or earths are clean and corrosion free and i would recomend verifying with a good ohm meter .

Timely advice, I did this kick-starter no-no, but haven't run the bike yet.

 

[hva-factory]

Watch the YouTube videos by typing: Hva Factory Everything you need to know on clutches is there****************************************


Andy