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Discussion Starter #1
2012 TRX420FPE unit had been slipping in higher gears in 2wd, 3rd and up, under acceleration. This slipping is just like a car with a manual transmission under acceleration and you push in the clutch pedal, immediate rev and loss of acceleration. No noises like gears teeth slipping on teeth, just disengagement of power.
We pulled the front case, saw the centrifugal weights and drum looked like they had gotten hot. Replaced all these components with new Honda and replaced the clutch plates with new Honda as well. Replaced the springs with EPI economy which should give a small, 500 rpm, stall.
All assembled back, adjusted the clutch bolt on the front cover per instruction, CCW until you feel tension, then 1/4 turn CW and lock it down. In 2wd, under hard acceleration, it still goes into a freewheel situation of rev and loss of power? Then adjusted the clutch tighter and looser, but no change. Put the unit in 4wd and it pulls hard thru all gears with no felt slipping?
A little more background, the rear solid axle broke a while back, it's new. The rear differential grenade on a ride, it's new along with the propeller shaft and u-joint. Pretty much everything is new except the gears in the rear end of the case! I don't understand the continued slipping with all new clutch components!
The Honda manual mentioned slipping could be caused by a "faulty clutch lifter"? Anyone had issues with the lifter assembly? We did the inspection as recommended by the Honda manual and the race and bearing rotated freely. Really confused on what could be wrong beyond the pieces we have replaced.
Thanks,
 

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Scot, because you experience this slipping issue in 2wd but not in 4wd, the problem is not related to your clutches. Your rear wheels are not driving like they should. When you are in 4wd, the front wheels are doing all the pulling so you do not experience slip. Something is not installed correctly in your final rear drive/rear axle. There is a key missing or stripped splines, or something like that.

When you take the final drive apart, it will be pretty obvious where it has been spinning because it will be all galled up.
 

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Yep, if it doesn't "slip" in 4wd it's something in your rear end.

The same shaft powers the front and rear diffs, so it's from the driveshaft back somewhere.
 

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I would take a good look at the rear prop shaft possible spline or yoke worn out and slipping there would be less stress on the shaft when the bike is in 4 we, that's my guess anyway.


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Discussion Starter #5
Thanks for the reads and comments guys! We still haven't figured it out, but trying to eliminate possibilities as we go. We are going to check the propeller shaft connection to the pinion and to the output shaft.
Another person told us to check the springs in the clutch hub, that if they were stretched this could result in clutch slip? We installed new EPI springs in the centrifugal hub, so that should be good.
 
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