Factory Clutch Modification for TRX450R
This modification will make your TRX clutch like the dirt bike by removing the judder spring, seat, and engagement clutch disc. This modification will result in longer clutch life by reducing slippage and provide a more positive clutch engagement.
While I had my clutch apart I also bead blasted the steel discs for longer clutch life and more positive engagement.
Remember if more then one bolt holds anything on loosen all the bolts in a pattern before removing to avoid stressing the bolts, threads in the hole, and the piece you are removing; tighten in the same manner.
Tools Needed:
1. 8mm Allen socket or wrench
2. 8mm 1/4" drive and ratchet
3. 10mm 3/8" drive and ratchet
4. 3/8" torque wrench
5. Pick tools
6. Jack
7. Needle Nose pliers
Materials Needed:
1. #7--DISK, CL FRICTION: 22201-MEB-670
2. O-RING, CLUTCH COVER (Optional): 11352-HP1-670
3. Transmission oil
4. Container (to soak clutch disc in)
5. Waterproof grease
6. Loctite
***Breakdown of the Clutch***
1) Soak your new #7 clutch disc in oil. Note: If you are replacing all the discs soak them all in oil.
2) Use an 8mm Allen head socket to remove the rear brake pedal, and then remove the return spring.
***Remove this bolt***
3) You have two choices here:
a) Drain the transmission oil and pull the clutch cover
b) Do not drain the transmission, instead jack up the right rear tire and lean the quad over and pull the clutch cover (this is what I did).
***Jack***
4) Remove the 6 bolts holding the clutch cover on (8mm socket). Note: the numbers in the picture are the order I went in, break them all loose in this order and then remove them all.
***Remove these 6 bolts***
5) Remove the clutch cover. If you have the ATV leaning over far enough the oil will not drain out (You may have to tap the cover gently to get it off).
6) Remove the 5 bolts and springs holding the pressure plate (10mm socket). Note: the numbers in the picture are the order I went in, break them all loose in this order and then remove them.
***Remove these 6 bolts and springs***
7) Remove the washer and bearing (might have stuck to the pressure plate).
***Washer***
***Bearing***
8) Remove all clutch discs (note the last disc is #6 and it is smaller then the other fiber discs…discard #6). With the ATV leaned over I had to use some small pick tools to get the last 4 or 5 discs out.
9) Remove the judder spring #12 and the judder spring seat #5 and discard.
***Remove all these items and discard***
10) Remove your new #7 FIBER DISC from the oil it is soaking in and install it first. Next install a metal disc, then fiber, then metal so on, the last disc you install should be a fiber disc. If not, take them all out and start over.
11) The final fiber disc, red arrow, needs to be installed in the shallow area of the clutch outer #2. All the other discs, blue arrow, are installed in the deep area.
***Last disc goes in shallow area of clutch outer***
12) Install the bearing #23 (give it a good coat of oil).
13) Install the washer #22 (give it a good coat of oil).
14) Install the pressure plate, 6 springs and 6 bolts and Torque to 9 lbf/ft.
***Torque to 9 lbf/ft***
15) Coat the O-ring on the clutch cover with oil and install the clutch cover. Note: I re-used my O-ring and will continue to until it begins to leak, I do have a new O-ring on the shelf…it is good to keep consumable parts on hand.
16) Tighten the 6 clutch cover bolts securely.
17) Preventative maintenance: clean up the rear brake pedal mounting area, apply waterproof grease and reinstall the bolt, also since this does hold the brake pedal on I like to apply Loctite. Note the grease seals in the brake lever. Torque to 20 lbf/ft.
***Brake bolt***
***Torque 8mm brake bolt to 20 lbf/ft***
18) Reinstall brake pedal return spring.
The End!
