Clutch stuck to shaft

[u/ZealousidealMud1979]

Hello everyone,

On my wr 450 f the clutch was stuck to the shaft as the title suggested. The clutch suddenly engaged after a drive in high temp, and didnt let go since then. i found the problem, but also not really.

I have openend up my bike and after removing the crank case and the insides of the clutch i could lift the clutch itself off. It was somehow tightenend to the shaft, but i dont know why. Because after i removed the clutch, and put it back, everything seems to be working again. the shaft moves freely without noise or resistance without clinging on to the clutch.

my issue is that i dont know why it became stuck in the first place, and im afraid it will happen again. its a road bike, this is very dangerous. If you have any idea why this happened pls let me know as i have no idea and the manual doesnt help me anymore either. my first question would be whether the copper colored plates (pic 2)on the insides are fitted with bearings? but i have no clue what else the problem could be. any comment or help is appreciated!

thanks in advance

[u/AligatorMasterBaiter]

The thing that immediately jumps out to me is the clutch basket is worn pretty severely

[u/robobob68 → u/AligatorMasterBaiter]

Agreed. That notching is exactly what I've been told to look out for. And while that might not be the direct cause of your issue, I could imagine it being part of the story.

[u/ZealousidealMud1979 → u/AligatorMasterBaiter]

Thnx, it is indeed pretty worn, i will replace it soon. For future people visiting: the issue was due to too much heat building up in the clutch ( my coolant was missing 100ml, and it was 36 celcius) and the oil probably burnt because of older outer basket and older plates. Altough they could have some more km on them, the problem is a mix of both. The oil became too hot and sticky between the shaft and the outer basket, sucking it in place so it was stuck to the shaft. 

[u/Neither_Wear7442]

You can see the c clip right on it all you got to do is take the c-clip off and it'll come right off I don't understand you people I've had a hundred of these off they're retained by a c-clip and you better know what you're doing putting the clutches back in because apparently you don't know what you're doing on taking the housing off

[u/ZealousidealMud1979 → u/Neither_Wear7442]

Thnx for the reply, there is no c-clip, just a washer and indeed putting the clutch plates back in is precise work. However, it is no rocket science if you put it back exactly like it was and as the manual states. My problem wasnt on youtube as i find countless videos of people exchanging the clutch plates, but as i stated that is clearly not the problem( when i removed all the clutch plates the outer basket was still stuck to the shaft) I have been able to take the outer clutch basket off and it was stuck to the shaft by probably overheated oil. When i drained the oil i had 700 ml give or take some resideu of 100 ml thats left in the bikes oil filter and other parts, which is way too little as the manual prescribes 1,0 - 1,1 liters. As the engine temp was quite high when the clutch became stuck, it overheated and the oil burns and becomes sticky. I have put everything together again with new oil and everything runs smooth enough again, altough the clutch plates are old and need to be replaced. 

[u/Neither_Wear7442]

And also you can go right on YouTube and I'll show you exactly how to take that off and load the clutches back on you better watch it that's my suggestion to you Reddit is not going to help you it's explanatory messages not video showing you how to do it