Clutch replacement help - Honda Foreman Forums : Rubicon, Rincon, Rancher and Recon Forum
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post #1 of 14 (permalink) Old 03-01-2017, 01:35 PM Thread Starter
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Clutch replacement help

I am still getting clutch slip in 4th and 5th only when the quad is cold. I have adjusted it correct and changed the oil so it's time to replace the clutch. Can someone give me a list of parts to get that are clutch related as I only want to open it up once. Thanks
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post #2 of 14 (permalink) Old 03-01-2017, 02:23 PM
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Still a 2012?


Honda ATV Parts 2012 TRX500FM CLUTCH Diagram


If it were me, I'd replace 12 and 12. My guess is the drum will be grooved. Safe to figure on doing 3 and 4 (discs) on the change clutch while you're in there too


If you have a lot of miles on it, you might also consider 26, 10.


17 and 18 are considered "buy new" nuts, but I normally reuse the old ones.


Get a tube of Hondabond/ Yamabond/ Threebond to use on the front case when you reinstall it.


Be sure and break loose and grease your clutch adjuster screw while you have the front cover off.

"The Good One"
2009 Foreman 500FM Green
27" Execs on Rubicon rims, Perfex
Heated grips and Thumb , HID's
5K Viper Max winch

"The Wreck"
2009 Foreman 500FM Green
Perfex with HL springs
27" Mudbugs on Rubicon rims
Heated Grips and Thumb, HID's
4K Viper Max winch

"The Project"
2006 Foreman 500FM Green
27" Titan 589's Perfex with HLsprings
3K Superwinch winch

"Sandy" aka the wife's
2009 475 Rancher AT Tan
26" Mudbugs on Rincon rims
Warn winch. Foreman pod light with HID, SRA gear reduction
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post #3 of 14 (permalink) Old 03-01-2017, 02:51 PM Thread Starter
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Is the clutch adjust screw available to buy ? Last time I adjusted it one lug broke
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post #4 of 14 (permalink) Old 03-01-2017, 02:54 PM Thread Starter
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Also. Is there a gasket on the front cover ? And is there any special tools I may need ?
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post #5 of 14 (permalink) Old 03-01-2017, 03:17 PM
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#15 is clutch adjustment screw


Honda ATV Parts 2012 TRX500FM FRONT CRANKCASE COVER Diagram


Doesn't look like there's a gasket on the 2012. It's pretty much a 420 engine with a few changes, and the 420's just use Hondabond between the cases.


You'll need a puller to get the cent clutch off. I use a cheap 3 jaw puller I bought on Amazon.


https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1


Impact will help get the clutch nuts off. If you don't have an impact you can stick a leather welding glove in the gears to keep the clutches from spinning while you break the nut loose. The leather will keep the gears from spinning but won't hurt anything (except the glove).


Other than that it's simple hand tools. You can stand the machine up on the rear rack and work on it standing up. That's how I did it on the 07 Rancher I had.

"The Good One"
2009 Foreman 500FM Green
27" Execs on Rubicon rims, Perfex
Heated grips and Thumb , HID's
5K Viper Max winch

"The Wreck"
2009 Foreman 500FM Green
Perfex with HL springs
27" Mudbugs on Rubicon rims
Heated Grips and Thumb, HID's
4K Viper Max winch

"The Project"
2006 Foreman 500FM Green
27" Titan 589's Perfex with HLsprings
3K Superwinch winch

"Sandy" aka the wife's
2009 475 Rancher AT Tan
26" Mudbugs on Rincon rims
Warn winch. Foreman pod light with HID, SRA gear reduction
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post #6 of 14 (permalink) Old 03-01-2017, 03:50 PM Thread Starter
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This is starting to sound like it's out of my capabilities
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post #7 of 14 (permalink) Old 03-01-2017, 04:13 PM
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It's really not that bad


Undo skid plate and floorboards


Stand wheeler up on rear rack.


Undo all the bolts holding the front cover on, and take it off.


Undo clutch nut on centrifugal clutch, remove it. Undo 4 bolts on top of change clutch, and then nut on change clutch, remove it.


On a table, take the clutches apart, replace the parts I mentioned above, and reinstall clutches.


Sealant on front cover, bolt it back on.


Done.


Think of it as a puzzle for adults.

"The Good One"
2009 Foreman 500FM Green
27" Execs on Rubicon rims, Perfex
Heated grips and Thumb , HID's
5K Viper Max winch

"The Wreck"
2009 Foreman 500FM Green
Perfex with HL springs
27" Mudbugs on Rubicon rims
Heated Grips and Thumb, HID's
4K Viper Max winch

"The Project"
2006 Foreman 500FM Green
27" Titan 589's Perfex with HLsprings
3K Superwinch winch

"Sandy" aka the wife's
2009 475 Rancher AT Tan
26" Mudbugs on Rincon rims
Warn winch. Foreman pod light with HID, SRA gear reduction
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post #8 of 14 (permalink) Old 03-02-2017, 08:03 AM
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Love this reply - basically told you how to do it in under 100 or so words...

You can do it bud...like Jeep says - think of it as a challenge - then when you succeed, it is that much sweeter and you will gain the knowledge and experience to progress onto bigger things...

2002 450s
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post #9 of 14 (permalink) Old 03-02-2017, 09:57 AM
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Watch this video Crombie.


Engine is on the bench, but you can see how it comes apart. About the 5 min mark is where he takes the front cover off.




You can do this with the engine in the frame, and if you stand the wheeler up on the rear end you'll be working at chest level so not too bad.

"The Good One"
2009 Foreman 500FM Green
27" Execs on Rubicon rims, Perfex
Heated grips and Thumb , HID's
5K Viper Max winch

"The Wreck"
2009 Foreman 500FM Green
Perfex with HL springs
27" Mudbugs on Rubicon rims
Heated Grips and Thumb, HID's
4K Viper Max winch

"The Project"
2006 Foreman 500FM Green
27" Titan 589's Perfex with HLsprings
3K Superwinch winch

"Sandy" aka the wife's
2009 475 Rancher AT Tan
26" Mudbugs on Rincon rims
Warn winch. Foreman pod light with HID, SRA gear reduction
jeepwm69 is offline  
post #10 of 14 (permalink) Old 03-20-2017, 03:28 PM Thread Starter
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Sorry to dig this up but at the start you said to get parts 12 and 12. Did you mean 11 and 12 ?
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