Hi ALL,
HELP!!
I just picked up a 2001 400ex for 900$ and the only problem Im having with it is a CRAZY HARD clutch pull. I tore into it and removed the clutch plates but they seem to be well within spec. I noticed one thing that didnt look right, a small amount of play in the basket. Please see the video. IS this amount play OK.. BTW I followed the service manual and checked the ID and ODs and everything seems to be it spec. see my youtube video.

400ex clutch basket play - YouTube

Thanks,
Tim

 

I would say that play is normal. As far as the hard pull, you should try to isolate where that is coming from. Remove the cable from the lever and see if the lever itself is bound up. Then remove the cable from the clutch side and see if the cable moves freely inside of its sheath. Then pull the clutch arm by hand, or with vise grips or something and see if that's where the bind is. My guess it the cable is bad. It should move as smooth and easy as silk.

 

I dont know about the play you have in the basket.
A super hard clutch is usually 1 of 2 things. Worn clutch cable or grooves in the clutch basket itself. You want to check the basket where the tabs on the fibers come in contact with the basket. That is where you will find the grooves.

 

I can see some grooves in the basket slots but they don't look bad. They can be filed out with no problems.