HONDA TRX 500 FOREMAN 4×4 / TRX 500 RUBICON CLUTCH KIT INSTALLATION INSTRUCTIONS

By | December 21, 2013

Download ATV’s can be dangerous. EPI has no control over the use of any part. EPI expects the customer to exercise good judgment as to the proper selection, installation, use and maintenance of any part. EPI assumes no responsibility for damage or injury of any kind because of misuse, improper installation and improper application of any parts in any way by any person. Contact your local dealer to schedule installation of this clutch kit if you are not a qualified ATV mechanic. This product is NOT to be installed on any ATV that will be used by any person under the age of 16. TOOLS NEEDED TO INSTALL CLUTCH KIT -Set of metric sockets -27mm socket -Phillips and flat tip screwdrivers -Torque wrench -Spring tool or needle nose pliers -1/2″ impact wrench -Honda clutch tool #07ZMC-HN2A100 -Honda motor oil -Yamabond Semi-drying liquid gasket (or similar semi-drying liquid gasket) GASKETS NEEDED TO INSTALL CLUTCH KIT – None, only need tube of semi-drying liquid gasket 1. Remove the key from the ignition switch. Remove the left and right side lower front fenders. Remove the left and right side inner fender wells and the metal brackets holding them on. 2. Remove the oil drain plug from the oil tank and the motor (one at a time). If you can carefully drain the oil into a clean container you should be able to reuse it. Remove both oil lines going into the oil tank and unplug the oil sensor at the bottom of the tank. Remove the five long bolts that hold the oil tank to the crankcase, keep track of each bolt length and location. Once all the bolts are removed slowly slide the oil tank away from the crankcase. Check to make sure the rubber o-rings are in place and in good condition where each oil line goes into the tank and where the tank connects to the crankcase cover. 3. Remove the upper side body panel by the shifter knob. Remove the cotter pin and the pin for the shifter linkage. Using a screwdriver push in on the end of the spring and gently pull down on shifter linkage. 4. Remove the left side plastic motor cover and unplug the wire harness located behind the cover. Remove the metal bracket that the plastic side cover was bolted to. Unbolt the solenoid on the left side of the motor (looks like a starter) and let it rest on the foot rest. 5. Mark the gear shift linkage where it fits onto the splined shaft coming from the motor with a paint marker or lightly tap with a hammer and a chisel or punch for proper alignment when assembling the machine back together. Loosen and remove the bolt and clamp holding the shift linkage to the shaft and slide linkage off of the shaft. 6. Remove all of the crankcase bolts; keep track of each bolt length and location. Slowly slide the crankcase cover off the machine. It should slide easily, if it doesn’t check to make sure all of the bolts have been removed. If the cover seems to be stuck it might be rubbing on the rubber pad on the skid plate, if this is the case gently push up on the cover or down on the skid plate to slide the cover off the machine.

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