• First things first you need to make sure that you have a clean machine to work on, dirt is the last thing you want in your motor.

(1)

• You must drain the engine oil before hand , if you have just changed it try draining it into a clean pan .
• Next you will need to take off the side case cover, try this little trick to keep track of your bolts and keep their placement correct,  not all are the same length which could result in a stripped hole.

(2)

• Start by removing the two bolts, that hold the oil pipes onto the right crankcase cover, remember to  remove the dowel pins, and o-rings, followed be the remaining cover bolts.
• When your ready to  remove the cover you must  turn and hold the clutch arm counterclockwise to disengage the arm from the pressure plate.

(3)

• Inside the clutch cover will remain the clutch arm and return spring, be sure to check over for any damaged or highly worn parts.
• Following you will need to remove the five clutch spring bolts that hold the pressure plate on the clutch pack, you will need to remove these in a crisscross pattern, just a few turns at a time on each bolt to keep from getting the pressure plate in a bind.

(4)

• Remove the pressure plate, clutch discs and clutch plates, set them to the side for know we will inspect them later.

(5)

• It is very important to check the pressure plate's surface for any wear from the friction plate spinning against it, this is often over looked  and can lead to a clutch still slipping after a kit has been installed. Replace if there is any sign of adnormal wear, you can normal find a step up on the inside surface of the plate.
• (Note high wear on this pressure plate.)
• Inspect the clutch boss as well for the same damage, replace both if they show any signs of wear at all.
• ( A Hinson Clutch Plate and Boss is a great setup if you plan to push your motor to the limits.)

(7)

•  Check for any wear on the clutch basket. Check the slots for nicks,indentations or abnormal wear made by the clutch disc.
• (Note in the picture above the indentation worn into the slots of the clutch basket.)
•   Indentations or "grooves" will cause the clutches to grab on the release of the pressure plate, which leads to poor clutch performance.  Some of these grooves can be filed back flat,but this will only cause the same problem in a shorter peroid of time, as the clutch plates will hit harder and groove faster because of the added clearance.
• Your best bet is a Hinson Clutch Basket, the higher grade metal will hold up to the abuse for a longer peroid of time, with out notching like the O.E.M unit, be sure to pick up  Hinson pressure plates and bosses, they are a must if you have done any major motor mods on your Honda 400EX.

(8)www.hinsonracing.com Ph. 909-946-2942

• For inspection of your clutch disc and plates you will need to have a vernier calipar . Begin  by checking the disc for signs of scoring or discoloration. Follow by measuring the clutch disc thickness, it shall be no smaller than (0.106in)
• Check your clutch disc for discoloration caused by heat. Check the plate for  warpage on a surface plate, the warpage should not exceed more than (.006in) at any point around the plate.
• If you are only going to replace the clutch disc and plates you are ready to install . I have made a few notes that should make things go easier.
• Always begin with a clutch disc followed by a plate.
• Just snug the clutch spring bolts when reinstalling, they can pull easily.
• Alway replace the clutch cover gasket, the clutch cover is used to transfer oil throughout the engine and you do not want to plug up any holes with silicon.
• Be sure to turn the clutch arm in the clockwise direction to engage it with the pressure plate.
• Just snug the clutch cover bolts about (86 inch pounds) the threads will pull is you over tighten.

• If you are installing a new clutch basket, you will need a Motion Pro Clutch holding tool. It allows you to hold the clutch boss while removing and installing the clutch lock nut.
• Remember to unstake the clutch lock nut before removing .
• After removing the clutch basket be sure to inspect the clutch guide outer for wear. It should measure a service limit I.D. of (0.868in.) and a O.D. of (1.098in.)
• Here are a few tips to remember when reinstalling the clutch basket.
• Alway use a new clutch lock nut.
• Retorque to (80 foot pounds)
• Remember to stake the new nut.

• Next reinstall the clutch pack, clutch cover, and motor oil.
• Have a great ride

HERE IS THE LIST OF OEM OF FACTORY PARTS YOU CAN PURCHASE THROUGH US FOR YOU PROJECT.

OEM PRESSURE PLATE

OEM CLUTCH BOSS (INNER)

OEM CLUTCH BASKET

OEM CLUTCH COVER GASKET

OEM  CLUTCH LOCK NUT

OEM CLUTCH BASKET GUIDE

OEM O-RING (FOR OIL PIPES 2 REQUIRED)

OEM O-RING (INSIDE CLUTCH COVER)