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Discussion Starter #1
2005 Honda Foreman 500ES (TRX500FE) Clutch Install

Tools required:
10mm socket w/ 6â€
 

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Discussion Starter #2
3. Remove the cooling fan. (10mm socket) unplug electrical connections, but leave the vent attached. I pulled the fan out and tucked it out of the way in the right fender well.


4. Drain the oil from the motor. Remove oil lines from the crank case cover, make note of which one goes where and mark them along with the two bolts. (10mm socket)

As an update to this. It is easier to stand the bike on its tail and remove the skid plate to access the bolts a bit easier. In addition you will not need to pull the clutch off. Just be sure that the clips do not fall nto the motor. Set the bike down and then procedd w/ changing the oil and checking for leaks.
 

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Discussion Starter #3
5. Remove the crank case cover bolts, there are two different lengths, make note of which size goes where (its pretty obvious though) (10mm socket) Remove the cover. Do not be as surprised as I was when pieces come falling out. The clutch adjuster bearings and two washers will most likely fall out.


6. Use the 27mm socket and impact to remove the nut on the crank. This is where the instructions say use the Honda Clutch tool, but the impact should be able to spin it off alone. There is also a washer behind that nut.

7. Use the wheel puller to remove the clutch assembly. I rented a 3-jaw puller from AutoZone. This is a little tricky since the backside of the clutch is round, the jaws kept wanting to slide off. Be patient, it will grab it and you can pull it off.
 

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Discussion Starter #4
8. Place the clutch on to a flat stable surface. Take the flat screwdriver and push out the “Eâ€
 

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Discussion Starter #5
9. Pour some fresh oil on to the clutches and reinstall the assembly. I helped it along the shaft with a soft dead blow hammer. Just be careful no to damage the threads. Put the washer back on and tighten the new nut to 87ftlbs with the torque wrench and “re-stakeâ€
 

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A+
 

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excellent
 

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Discussion Starter #8
This is my mechanic giving me looks, as she tries to put the plastic back on.
 

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Truegrit you answered all of my questions. Thanks. Cute mechanic you have their. I'm guessing 3 or 4 right. I've got a 4 yr old and a 9 yr old.
 

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QUOTE ("raveer2000":wx9ukewi)
Truegrit you answered all of my questions. Thanks. Cute mechanic you have their. I'm guessing 3 or 4 right. I've got a 4 yr old and a 9 yr old.
Thanks. Your close, she'll be 2 in July.
 

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Just curious?

I had my bike stood up today (I am building a custom belly pan and front skid plate) and I had the stock one off. There is a ton of room under that plastic pan. Do you think the clutch could be pulled off that way without having to remove all the plastic. It looks like you can get to everything except maybe the fan. Just wondering.
 

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Discussion Starter #12
I don't think the front cover will fit through, ecspecially with the Electronic Shifter out front. Plus I don't think you can see it in the photos, but the shifting shaft stick out about 6-7 inches beyond the front of the motor. I think thats where the problem would be.
 

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I didn't even think about that. It was worth a try though.

Thanks
 

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QUOTE ("raveer2000":eek:gqe299u)
Just curious?

(I am building a custom belly pan and front skid plate)
Rectangular road signs make excellent skid plates for A-arms, full body, swing arm, and they are also good for fender repair.
 

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Discussion Starter #15
Oooh there's an idea. There are still a few laying on te side of the interstate from the hurricanes last year.
 

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They can be shaped up pretty easily with a sawz all and they are pretty durable as well. A few holes drilled, no $$$$ and yes sir your on your way.
 

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So does a diamond plate truck tool box. I am using the bottom of the box(smooth) for the belly pan and the lid of the box for a one piece skid plate to replace all of that plastic.
 

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i got one of those signs sitting out front of work guess i am gonna get busy
 

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That is a good idea, I have one of those sitting on the side of my house, and I just busted the He11 out of my fron t bash plate, I think i better get busy too.
 

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I like the toolbox idea also.
 
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