How to Replace your Clutch

Photos by Adam Campbell

It’s only a matter of time before your machine’s clutch will need maintenance. When that time comes you can take your quad to your dealer for repair or go at it yourself.

If you haven’t replaced your own clutch because you’re a bit fearful of doing something wrong, then this step by step feature is just what you need to gain the courage to take on the project yourself and save some money.

No more being intimidated, replacing your clutch assembly isn’t really that difficult, especially if you do it like ATV Superhero Wayne Hinson does in this step by step picture demonstration.

ImageWayne Hinson replaced the stock aluminum clutch basket on Gary Denton’s TRX250R with an unbreakable steel unit that he made in 1990. Soon after, the improvements that Wayne made to Gary’s race quads were made available to the public and Hinson Racing was born. Today, with fulltime help from sons Bryan and Ron, the Hinson family’s clutch component company is one of the most successful family run aftermarket business in the motorsports industry, and Hinson Racing components are now a staple in ATV and Motorcycle racing all over the world. Before you buy stock clutch replacement parts we highly suggest you upgrade to Hinson Racing components instead. See all that’s available for your ATV at  hinsonracing.com

ImageOkay, on with the project. Wayne recently replaced the OEM clutch system on a 2010 Yamaha YFZ450R while photo extraordinaire Adam Campbell shot photos of his every move. The following is the correct way to replace your clutch assembly…..
Begin by removing the clutch cover. Wayne uses a cordless impact driver.

ImageNext remove the pressure plate.

ImageWith the pressure plate removed the clutch plates and spacers are now visible.

ImageRemove the top hat.

ImageStraighten the locking tab on the inner hub nut.

ImageRemove the steel and fiber plates.

ImageRemove the inner hub nut.

ImageRemove the inner hub.

ImageRemove the washer between the innner hub and the clutch basket. Be sure to maintain this in the correct order.

ImageRemove the clutch basket.

ImageBe careful not to drop the clutch basket.

ImageHere Wayne compares the stock basket and the Hinson Racing steel clutch basket.

ImageBefore Wayne installs a new Hinson Racing steel clutch basket he makes sure it’s clean as it can be. For this install Wayne chose a steel unit, but light weight aluminum baskets are also available at Hinson Racing.

ImageGet the washer that was located between the clutch basket and inner hub.

ImageClean the washer and install it between the clutch basket and inner hub.

ImageClean the threads on the inner hub nut. Wayne uses contact cleaner to make sure the threads are as clean as possible.

ImageClean the threads in the main shaft.

ImageHere Wayne installs the Hinson Racing slipper clutch assembly.

ImageUse Loctite 272 on the main shaft threads and the inside threads of the nut.

ImageHold the inner hub of the slipper clutch with a clutch tool like this one.

ImageInstall the nut to secure the Hinson Racing Slipper Clutch assembly.

ImageTorque the inner hub nut to the proper torque as per manufacturer’s specs.

ImageInstall the new fiber and steel plates maintaining the recomended stack height shown in the instructions. Before installing Wayne suggest that you soak your fiber plates in oil first. In case you didn’t know, it’s one stop shopping at Hinson Racing, they make a full line of fibers, steels and clutch springs in addition to all the other high performance clutch products available for your ATV.

ImageInstall the original top hat.

ImageInstall the Hinson Racing Slipper Clutch pressure plate.

ImageLine up the spring clamp with the small tool.

ImageInstall the screws in the pressure plate. Wayne uses his trusty T-handle wrench to get the job done.

ImageTorque the bolts to the manufacturer’s specs.

ImageInstall the clutch cover and your clutch removal / install is complete.

ImageTesting is the last step of the project and the most fun. Brian Hinson seen here doing both.

If you want the same clutch system that just about every ATV and motorcycle motocross racer uses check out hinsonracing.com to see all that’s available for your specific machine.

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