I picked up a new basket and clutch plates to replace the clutch and plan on starting it next weekend. Looking at the Clymer manual it doesnt seem to hard but are there any special tools I should pick up for the job? The manual said something about a clutch removal tool to get the locknut off without it turning on you. I have never done a clutch before so I just want to get right the first time and not screw it up.

 

Why did you buy a new basket?? The only reason to need a new basket would be major grooves in the tabs from the clutch plates or one or some of the tabs being broken off. Even if there are grooves on the basket tabs you can cheat ONE time & file off the grooves off with a flat coarse file & then polish them up smooth with a fine file. I did this with a 400ex basket with no negative results & got the idea from a well known ATV magazine's tech article.

Probably the most important thing to do is soak the new fiber disks in oil for at least 1 hour prior to installation & follow the Clymer and take your time.

Oh... and use a thin bead of Ultra Black RTV on the gasket ( engine & case sides ) it will help hold the gasket in place & prevent a leak when all done.

 

I was able to pick up the new basket and clutch plates form a unused 05 For $150. It was a good deal so why not replace it all while I am in there anyway?
The quad is 10 years old and I dont know what I will find when I get in to do the job so its better to have the parts on hand if any problems should arise.

 

The center nut, that hold the clutch on, is hard to remove. You need the holding tool, or an impact gun. I tried doing it, without either tool. It broke the basket. You have a new basket, but have to get it tight. I have also heard that a belt wrench for and oil filter will hold it, but haven't tried that trick.

 

Its best to use a impact wrench,with the clutch removal tool that they recomend in the manual you run the risk of breaking the posts on the preasure plate.

 

Thanks for the help. So if I just use a impact wrench I dont need the clutch tool? Or will I also need to tool to keep the clutch from turning while using the impact wrench? I just want to be sure.

 

The impact from the impact driver will be enough to do the job...