clutch cover

[99400esex]

Hey guys, how do you install the clutch cover case on the motor and get the little arm to install properly? I cant seem to get it in there and get enough tension on the clutch cable. Thanks.

[hocman123]

well first just to make sure u should have a spring on the end of the level in a little hole and the other end should be in a tiny hole on the case and when u are putting it on have the lever faceing u and u should just be able to swing it around and it will grap.

[99400esex]

Thats what we have been doing, but when we hook the cable up to where it grabs the part on the arm there is nowhere near enough tension on the cable or on the lever up on the handlebars. What do u think the problem is?

[hocman123]

well are u useing the same cable or a new one b/c i order a motion pro that would not work right on my quad once

[99400esex]

Nahhh its still the same stock cable that has always been on there. We have been messing with the little arm for awhile and cant figure it out. The little spring is in there where you said and everything. Just cant get any tension on the cable no matter what we do.

[hocman123]

umm well did u just replace or remove the cluch b/c maybe u put it in wrong or something but i can't really help with that to much i only did it once and it was a long time ago

[99400esex]

No i just removed the cover. I accidentally dropped a bolt down the hole where the timing chain is when I was doing my hotcam. That was the only way to get the bolt out.

[hocman123]

do u do have the cable mount in the case bolted on good

[99400esex]

yep those 2 bolts were definitely tight

[CJM]

If you look at the arm, it has a little spot in it that the clutch pin rides in. You gotta put it in the right way so this snaps over that little pin. It took me a good 10 mins to get it in right.

[99400esex]

What does the clutch pin look like

[NacsMXer]

Originally posted by 99400esex
What does the clutch pin look like

It's the "lifter piece" in this pic

http://img198.imageshack.us/img198/5410/lifter.png (http://img198.imageshack.us/i/lifter.png/)

[99400esex]

Originally posted by NacsMXer
It's the "lifter piece" in this pic

http://img198.imageshack.us/img198/5410/lifter.png (http://img198.imageshack.us/i/lifter.png/)

Well that explains it. The lifter piece on mine is broke. The little round part on the end of it is broke off. Ill have to order a new one, is it just called the lifter piece?

[NacsMXer]

Originally posted by 99400esex
Well that explains it. The lifter piece on mine is broke. The little round part on the end of it is broke off. Ill have to order a new one, is it just called the lifter piece?

It's common for that to happen, don't know why it does though. I looked it up for you, this is for a 99 like you got.

PIN, CLUTCH LIFTER
Honda part # 22847-HN1-010

Retail is $10.84 ;)

[99400esex]

Originally posted by NacsMXer
It's common for that to happen, don't know why it does though. I looked it up for you, this is for a 99 like you got.

PIN, CLUTCH LIFTER
Honda part # 22847-HN1-010

Retail is $10.84 ;)

Thanks bud, will order it tonite.:)

How do you get the pin out?

[CJM]

Originally posted by 99400esex
Thanks bud, will order it tonite.:)

How do you get the pin out?

Remove the clutch

If memory serves me right you should just have to remove the 5 outer bolts. FWIW those bolts just get tightened (not to hard either..more like snug) as there is no specified torque for them.

[99400esex]

Originally posted by CJM
Remove the clutch

If memory serves me right you should just have to remove the 5 outer bolts. FWIW those bolts just get tightened (not to hard either..more like snug) as there is no specified torque for them.

Those are the bolts that hold the springs in right?

[CJM]

Originally posted by 99400esex
Those are the bolts that hold the springs in right?

Yea I should say clutch cover is the actual term or something like that.

Its not hard at all, just dont torque down on those bolts, they can snap. I made mine snug with a 1/4 drive ratchet.

[99400esex]

Originally posted by CJM
Yea I should say clutch cover is the actual term or something like that.

Its not hard at all, just dont torque down on those bolts, they can snap. I made mine snug with a 1/4 drive ratchet.

Thanks alot man, you always have a good explanation for my questions lol. I ordered the part directly from honda and holy crap, The shipping rates were almost DOUBLE the cost of the part. Ridiculous. But I need the part so the quad can go back together.:mad:

[CJM]

^ Thats why its worth it sometimes to just order the part from the dealer itself and pick it up.

Smaller the part the more insane the shipping on some sites. I usually use service honda, they are pretty cheap in shipping.

[99400esex]

Originally posted by CJM
^ Thats why its worth it sometimes to just order the part from the dealer itself and pick it up.

Smaller the part the more insane the shipping on some sites. I usually use service honda, they are pretty cheap in shipping.

Yeah I wouldve picked it up but my dealer sucks. They probably woulda ordered the wrong part just like they did with my gaskets

[CJM]

That does suck! I usually look up the part number myself and make them order that so I only have myself to blame if I get the wrong thing.