How To Replace Clutch Plates 💪🏻🛠 on a Honda XR400R 🏍

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Replacing the burned up clutch friction plates on my 1999 Honda XR400R after the clutch faded out on a failed hill climb a couple weeks ago.
I put in a Tusk Heavy Duty clutch kit from Amazon. The kit included new pressure plates, steel plates, springs, and a crankcase gasket (which I didn't need because only had to remove the small clutch cover for this job).
The springs in this kit are noticeably heavier than stock, so lever pull has increased a bit. But, I think it'll improve initial clutch "bite" and better take advantage of the XR's low-end torque curve.

[@MarkM-ke6cn]

Thankful! Doing my 2004 this morning...it's been a solid and very reliable bike. The original clutch has never given me any indication of failing, even after 20 years of Idaho single track. Fingers crossed for 20 more!

[@ExtremeSportsWannaBes]

Glad the video was helpful. Those bikes will last forever 🤙🏻

[@adildewji]

Loved the video. Thank you!

[@ExtremeSportsWannaBes]

Glad you enjoyed it!

[@MegaRydog]

i am having similar issues but in my case yes i feel my clutch starting to slip but also back wheel spins freely when i try and get it in gear do u think its a trans issue?

[@ExtremeSportsWannaBes]

Hard to say without seeing it. It's possible to have both wheel spin and clutch slip (especially right when the clutch first starts to fail). Might want to check clutch adjustment first.

[@decentgarage]

Awesome video! Thanks for doing this. What footpegs are you running?

[@ExtremeSportsWannaBes]

Glad it was helpful! It’s a pretty easy job once you know all the steps. The foot pegs are XR’s Only brand. You should be able to fine them on their website.

[@iluvducttape1]

Fancy seeing you here

[@decentgarage]

@@iluvducttape1LOL best notification and random comment ever!

[@decentgarage]

@@iluvducttape1 I guess we both have clutches in the near future

[@iluvducttape1]

@@decentgarage lol mines just slipping when I first get on the throttle. Probably just needs adjusted but I was just curious what it would take to change it

[@ernestkuczek6496]

You didn't have to drain the oil before?

[@ExtremeSportsWannaBes]

Not usually. You can typically just lay the bike on its side to do clutch work.

[@macgarymusic]

I believe it's recommended to change the oil and filter if your clutch has just completely burned out since there will be burnt debris from the friction plates mixed with the oil. Although not absolutely necessary, it's a good rule of thumb to use new oil whenever installing new engine parts 👍🏼