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October 23rd, 2012, 11:08 AM   #1
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2004 fe 450 clutch issue

Hi guys
First post and first issue with my berg.
I cannot select neutral. If I come to a stop and try and engage neutral it wont go in no matter how hard I try.
However when moving forward and I dip the clutch I can select it!!! (easily)
Any ideas?
cheers Dave
weemo1rush is offline  
October 24th, 2012, 04:47 AM   #2
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Re: 2004 fe 450 clutch issue

Try going down from second instead of up from first
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October 24th, 2012, 07:25 AM   #3
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Re: 2004 fe 450 clutch issue

every dirt bike I've had has proved difficult to shift into neutral, but every one was fixed with a bit of TLC. A dragging clutch makes things much worse, so check that out first. If your slave and master cylinder are OK, and there's no air in the system I suggest you strip and rebuild the clutch next. You may find some warped plates which would explain the issue. Replace them and the world will probably be a better place.

On mine the inner hub and the outer basket were badly notched. Amazingly they responded very well to cleaning up with a file and I could select neutral when stationary a lot easier, although sometimes I still needed to 'fish around' a little. Whether this works for you depends entirely on the type of your clutch though (there are two to my knowledge; mine was the more conventional 'spline' type).

The other factor worth noting is the condition of your selector drum detent plate. If the neutral detent is worn, or the roller that drops into the detent is not too happy, or its spring is a little floppy, the chances of it slipping through neutral into first or second is high. Repair the roller, replace or bend the spring (easier said than done, I go for replacement every time!!), and replace the detent plate, or just file (or grind) the neutral detent a little deeper and leave the edges quite sharp. Too sharp and you'll tend to drop into neutral when shifting up from first in a hurry, but that's easy to fix by rounding the corners of the detent a little.

This was the case with mine too, and now I can always select neutral whenever I want...

A simple solution to an irritating problem, and you need only remove the clutch cover. Failing that, learn to shift into neutral just before you stop!

I hope that helps you in some way or other.

Cheers... Paul
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October 24th, 2012, 08:14 AM   #4
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Re: 2004 fe 450 clutch issue

would suggest new steels mate. I do a set of steels where the middle four are thicker at 1.4mm (usually 1mm) and this stops warping.

there is the chance that the slave seal is going as well.


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2004, 450, clutch, issue

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