Filed Under (Honda) by admin on 21-12-2013

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.

Incoming search terms:

2004 honda foreman rubicon clutch adjustment screw , how to pull the clutch on a trx 500 , cleaning out breather pipe on a 2005 peugeot 205 hdi sport , 2005 HONDA FOREMAN CLUTCH ADJUSTMENT , clutch adjustment for honda trx500 fa2 , removing the clutch on a honda rubicon , Foreman 500 Clutch Adjustment , honda rubicon shifter removal , honda rubicon foreman shifter linkage , honda trx 500 clutch , honda odyssey starter cut relay 1997\ , honda TRX 500 clutch removal tool , honda trx 500 how to rebuild transmission , honda trx 500 transmission malfunction , honda trx 650 clutch tools , where is the fly wheel on 2001 honda rubicon 500 , where is the clutch adjustment screw on honda e22 atv motor , trx 500 clutch puller size , shifter linkage on honda rubicon , internal clutch adjustment of a honda 400 foreman , how to replace one way clutch on honda trx500 2001 , how to replace clutch in 2006 honda trx 500 foreman , how do u clean a diff breather , honda foreman rubicon 500 whining noise , honda foreman adjusting the clutch , honda foreman 500 alighnment , 05 honda 500 foreman auto compression release problems , 09 FOREMAN 500 TIMING , 2004 handa foreman rubicon clutch asembly removel tool , 02 honda trx500 foreman rubicon repair manual , 2004 honda rubicon clutch slipping , 2006 Honda 500 trx transmission adjustment , 2006 honda foreman 500 clutch adjustment , 2006 Honda Foreman crankshaft inspection plug , 2006 TRX Rubicon Escape , 2009trx 500 have a radiator , 2013 honda foreman 500 clutch noise , 2013 honda foreman 500 diagnostic connector style , 500 rubicon clutch puller dimensions 40 mm , adjusting shifting linkage on honda 500 rubicon , engine breather on 207hdi , foreman 500 clutch wont adjust , honda 500 transmission , 02 trx 500 clutch noies

Comments are closed.

You might also likeclose