I have a 2003 z400. I have relaced the clutch cable. I replaced the stock clutch last summer with a tusk from rocky mtn atv. The clutch feels spongey. Also when the clutch is pulled in all the way, it will not roll if it is in gear. It has to be in neutral to roll. This is why I replaced the clutch cable. I looked at the clutch basket and it has marks in it but you can barely feel them with your finger.

Should it be able to roll with clutch pulled in and in gear?
1st to 2nd gear shift is stiff.
Clutch feels spongey.
Can the clutch basket be sanded a little? ( no big groves )
Also it jumps forward when shifting from neutal to 1st.

Any suggestions?
Thanks

 

Did you soak your friction plates in oil before you installed them? It sounds like the friction plates are resisting absorbing oil.......

 

no, I got in a hurry and didn't soak them. I guess I need to try a new set of plates. What does soaking in oil do for them? Just curious. Thanks

 

Soaking them just makes them able to "wick" oil into and out of the plates....... While the machine is running, if they are not already soaked with oil they get hot, glaze up, and resist the oil so they are not getting the proper lubrication. Once in the system they are not wet enough for long enough to really soak up enough oil to start the wicking process.

They do make plates that do not require oil soaking. I cannot recall off hand who makes them.

 

Thanks for your help. I am soaking a new set right now. Hopefully that will take care of the prob.

 

Inspect the basket really close too, any little "bur" will make a big mess.......

 

Today I wanted to do it only once so I put in a brand new oem clutch basket ( old one had only small rub marks on it ). I also put in all brand new oem clutch plates ( steels and fibers ), as well as new oem springs today. It has a new clutch cable, I put in last week. It shifts good now, but will still pull forward in first gear when clutch is pulled in. I have all the slack adjusted out of the cable at the lever. I'm lost as to why it is still pulling. Everything is brand new oem. Any Suggestions? I have verified all the parts are there compared to the manual. Thanks

I did soak the new plates in oil before installing them this time. I let them soak for a few hours.

 

What do you mean it pulls forward?

Do you mean that in 1st gear with the clutch pulled in the quad still moves? As if the clutch is not pulled in at all?

Or do you mean it "jumps" a little when you click it into gear with the clutch pulled in?