Another TRX450r with clutch issues.
Sooooo.... I bought an 07 TRX450r that needed some engine work. I re shimmed the valves, put on an aftermarket exhaust (Two Brothers), after market air filter, and cleaned, jetted, tuned the carb.
Quad starts on the first or second try every time now, runs smooth, and revs hard but I am having some weird Clutch issues.
The guy that had it before me had new clutches installed about 4 motor hours ago but about 8 months in time. Have the receipts and have personally inspected the discs, baskets, pressure plate, springs, yada yada yada....
The Quad had sat for the last 8 months, and about 2 weeks ago I bought it, loaded it up, took it home, and fixed the engine issues. I let the quad warm up to operating temp, dropped it into first and it killed the quad. Started it back up and tried again, same effect. I am able to shift into 2nd however and it now kill the bike, only lurch forward a few inches.
Took the trans cover off and the clutches were a sticky mess but it had been changed with Rotella White bottle so at least it was good oil in the case. Cleaned all of the plates and clutches, spec'd everything to make sure it wasn't warped... checked the clutch basket for grooving and everything was clean and smooth, mic'd the teeth on the the clutch basket and everything was within tolerance. Soaked everything in the Rotella, re assembled, and came back again with the same problem. Took all of the clutches out again, examined judder spring, inspected throw out bearing, and every part i can find and nothing seems to be bad.
Looked up a clutch diagram for a TRX450r and noticed i was missing a washer, part 22 from the throw out bearing. Ordered a new one and put it in and now the clutches will disengage some when standing beside the quad and pushing it while in first but you can still feel the drag and hear the plates and clutch discs rubbing as they rotate. Also when I added the washer i had to reduce all pull in the clutch cable just to get a tiny amount (1/8th of an inch) of play in the clutch.
I also noticed the diagram gave two different ways of installing the washer and lock washer for the clutch basket, Is one way better then another? and also I read on this forum, in another thread, that the last clutch plate goes in the shallow portion of the clutch basket.
See picture for example