2004 450 clutch problems ?

I was certain that my clutch was slipping, but I noticed it only in 4th gear (remember, my old bike is a 4 speed). It would jerk under acceleration. I wasn't surprised because it is the original clutch. This is my first 4-stroke, but 2 years of hard riding MX must be pretty good.

I opened it up yesterday to replace it. The old plates were still 3.0mm thick, the same as the new plates. Min service limit is 2.8. The springs were a little shorter (~2-3mm) than the new ones. The friction plates had very little wear.

After replacement, the pull felt about the same.

I havn't been able to test it yet, but I wondered why the old plates were slipping. Do they glaze or something?

Brent

They will harden and loose a little of their ability to hold under load.

However, when you say the bike jerks while the clutch is supposed to be slipping, it sounds more like the bike is popping out and back into 4th gear, which would be a worn 3rd and 4th pinion gear (main shaft), and a bent shift fork.

They will harden and loose a little of their ability to hold under load.

However, when you say the bike jerks while the clutch is supposed to be slipping, it sounds more like the bike is popping out and back into 4th gear, which would be a worn 3rd and 4th pinion gear (main shaft), and a bent shift fork.

grayracer,

The jerking occurs under throttle with the clutch fully released. If I shift into fourth and apply the throttle, it jerks repeatedly as long as I am on the throttle. It isn't a smooth slipping like I am used to with 2-strokes.

I initially thought it was popping out of gear too, but didn't think that was likely. Would you recommend a test drive with the new clutch to verify weather the condition was corrected and if it persists, pull the tranny apart?

Yeah. It looks like it's headed that way.

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