2007-2009 HONDA 420 RANCHER 2×4/4×4 CLUTCH KIT INSTALLATION INSTRUCTIONS

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ATV’s can be dangerous. EPI has no control over the use of any part. EPI expects the customer to exercise good judgment as to the proper selection, installation, use and maintenance of any part. EPI assumes no responsibility for damage or injury of any kind because of misuse, improper installation and improper application of any parts in any way by any person. Contact your local dealer to schedule installation of this clutch kit if you are not a qualified ATV mechanic. This product is NOT to be installed on any ATV that will be used by any person under the age of 16. Tools needed to install clutch kit – Metric socket set – 27mm socket – 1/2″ impact wrench – Torque wrench – Phillips and flat tip screwdrivers – Spring tool or bent pliers – 5mm Allen wrench – 10mm & 14mm wrench – 2 C-Clamps – Honda clutch tool #07933-HB3000A – Honda motor oil – Honda coolant – Honda Bond or Yamabond Semi-drying liquid gasket (or similar semi-drying liquid gasket) GASKETS NEEDED TO INSTALL CLUTCH KIT – None, only need tube of semi-drying liquid gasket ENGAGEMENT – 25-2,600 rpm’s 1. Remove key from the ignition switch. Remove the side panels from both sides. Remove both foot wells. 2. Drain coolant. Remove the oil drain plug from the motor; if you carefully drain it into a clean container you should be able to reuse it. 3. Disconnect shift motor (on electric shift models only). Remove coolant hoses. 4. Remove the bolts that mount the front differential to the frame, no other parts need to be removed. Carefully slide the front differential towards the front of the machine; you might need to lift up slightly to get the differential to move. Remove the drive shaft. Remove o-ring on output shaft (on motor). 5. Remove the fuel pump. 6. Loosen the front crankcase cover bolts, keep track of each bolt length and location. Slowly remove the crankcase cover. Carefully watch for o-ring shims and dowel pins that may fall out. 7. Unstake the nut holding the clutch on and remove nut. Using Honda tool #07933-HB3000A thread the large part of the tool into the center of the clutch. Tighten the center bolt on the tool while holding the large part of the tool with a wrench. This will pull the clutch off the machine. Place the clutch on a clean work surface 8. Using the c-clamps push down slightly on the outside cover and remove the four e-clips. Keeping track of which way they come off, remove the round metal plates one at a time. This will allow you to see the complete spring. Remove one end of each spring using a spring tool or needle nose pliers and then remove springs. Install the EPI springs by inserting the spring into the outer edge first. Using a spring tool or pliers (45 degree bent pliers work well) pull on the spring and insert the end into the hole. Install the metal plates and the e-clips. If you can’t get the plates to sit flat make sure each clutch arm is flat against the bottom plate of the clutch. Occasionally when you put the springs on, the clutch arms will pop up. Slide the clutch into the machine. The Sprague clutch is marked “outside” when installing make sure this is facing out. Torque clutch nut to 87 ft/lbs. 9. Clean the gasket surface on the motor and on the cover. Put a thin layer of Honda Bond or Yamabond semi-drying liquid gasket (or something similar as long as it is semi-drying) on the crankcase cover. Carefully install crankcase cover, do not force cover on. Torque bolts to 9 ft/lbs. 10. Install the fuel pump. 11. Install the o-ring on the output shaft (on motor) and install the drive shaft. Carefully slide the front differential back into place and mount to the frame. Install the coolant hoses. Refill your engine coolant to the proper level according to your owner’s manual.