[jbuddenberg]

i'm a bit stumped. 2005 Honda 400ex. Clutch is hard to pull. I know this because it's gotten worse and I can compare it to two other 400's I have. Tried the following:

1) Replaced clutch cable (easy logical step) - no help
2) Rebuilt clutch with Tusk kit - new plates, springs. Also got replacement arm that connects to clutch cable (in case it was boogered up) - no help
3) Replaced clutch handle assembly from another 400ex I have that was easy to pull. - A little better.

The only thing left I can think of is maybe the clutch plate is catching on the clutch on the way out. I checked for grooves and really looked OK. Can't think what else could be the problem.

Jimmy

 

[Here 2 help]

Two most common causes of heavy lever pull is a dragging or incorrectly routed clutch cable and heavier than stock clutch springs

 

[phil20]

i agree with you buddy, i had the same problem with my clutch cable, i swapped the perch lever, and cable. but i found out the problem was a bad route and it was becoming super heated by the exhuast and melting the plastic cover and cause a tighter pull. double check the cable condition again and the route before getting to the internals.

 

[chasemo12]

Im having this same issue currently, replaced the clutch arm as well as the return spring, got a new clutch cable, new tusk competition clutch with springs and i seem to have a weird play in my clutch arm. The clutch arm can be moved up and down when there is not much tension on it, when the clutch arm iss lifted up the pull is like notchy and feels like it is catching sort of, however when the clutch arm is down it is smooth, but as you pull in the clutch with the correct tension it lifts the arm back up and is mich harder to pull. pretty specific and dont know if anyone can help but thanks in advance.