P1000 Replacing clutch pack on the Beast

[Eltobgi]

Under $400=2 gallons Honda oil, 2 o rings, oil filter, dct filter, 1 clutch pack,...But the real cost is not being able to ride and for me that is the highest cost.

When I started it up today and pulled it out of the garage I reved the engine and it grabbed and I almost just took off! I spun a cookie and pulled it back into the garage and it was enough of a "fix" for me for another day! Weather is warming up and I'm going to take advantage! That is why I drove almost 200 miles today for filters when I had some on their way in the mail!

 

[Admin]

 

[Eltobgi]

Now I think I should have drove it at least another 6 miles

 

[1BadDart]

Is Honda taking the old clutches back as a core? If not I'd like to have one to take apart and inspect.

 

[Eltobgi]

They are already spoken for, sorry. No core on the clutch pack that I'm aware of.

 

[popeye]

They are already spoken for, sorry. No core on the clutch pack that I'm aware of.

Who are they going too?

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[JTW]

Interesting.. how
Long have you had yours?

 

[Eltobgi]

Who are they going too?

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@snuffnwhisky asked me if I would let Barnett Clutches use them for R & D! As any good forum member would I said yes! The goal=a better Aftermarket Clutch Pack I may get it back after and then @1BadDart would be the next in line

 

[popeye]

@snuffnwhisky asked me if I would let Barnett Clutches use them for R & D! As any good forum member would I said yes! The goal=a better Aftermarket Clutch Pack I may get it back after and then @1BadDart would be the next in line

Thats awesome. Good going

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[X4Dice]

Under $400=2 gallons Honda oil, 2 o rings, oil filter, dct filter, 1 clutch pack,...But the real cost is not being able to ride and for me that is the highest cost.

When I started it up today and pulled it out of the garage I reved the engine and it grabbed and I almost just took off! I spun a cookie and pulled it back into the garage and it was enough of a "fix" for me for another day! Weather is warming up and I'm going to take advantage! That is why I drove almost 200 miles today for filters when I had some on their way in the mail!

My dealer sold me Pro Honda HP4 0W-30 for winter months, it's a synthetic blend. I'm going to change oil next week. 6 qts of 10w-30 at -20 hurts.

 

[Eltobgi]

My dealer sold me Pro Honda HP4 0W-30 for winter months, it's a synthetic blend. I'm going to change oil next week. 6 qts of 10w-30 at -20 hurts.

Without seeing it in writing within the manual I couldn't do it! I most likely wouldn't be starting it when it is -20 below. If I had to I have heaters that I could put in the engine compartment that would help warm it up a little.

 

[Eltobgi]

Had it warming up over night...

The engine was warm to work on in my garage that was probably 30 above temp

 

[X4Dice]

Had it warming up over night...
View attachment 31219 View attachment 31220
The engine was warm to work on in my garage that was probably 30 above temp

I called honda directly. Got the # from the dealer, they told me it was approved for a wet clutch. That is why I asked.

 

[Eltobgi]

Kill the power

Unplugged 4 electrical plugs removed 8 bolts and case

 

[Eltobgi]

Pulled the clutch assembly...
Easy to see it's burnt

Inside of the case removed with outer gear

 

[Eltobgi]

When you have no friends, but have 2 knees

With downforce applied equally with the underside of knees clutch pack slid of without use of hammer

 

[snuffnwhisky]

Pulled the clutch assembly...View attachment 31227
Easy to see it's burnt
View attachment 31228
Inside of the case removed with outer gear

That looks like it got hotttttt.

 

[Eltobgi]

At this point I was supposed to take a break and grab a cold one but on my lunch break and in a hurry at this point


Old O-rings removed and new installed ensuring no debris and oiled. With clutch pack still in the same position carefully lined up new soaked clutch pack with splines on shaft. With the palms of both hands applied equal downforce while holding underside of gear with both hands and slid new pack on! Again without the use of hammer and socket

This pic shows different gaps on each side of the visible gear. The lower & larger gap faces outside

 

[Eltobgi]

Removed O ring to install new gasket

& reinstalled after new gasket was in place

 

[Eltobgi]

Lined up splines in both packs with gears installed and reinserted!

Still needs to go in about 2 inches. So grab a big hammer and hit it as hard as you can to force it in

Just kidding! Do not use a hammer!

 

[CumminsPusher]

Pulled the clutch assembly...View attachment 31227
Easy to see it's burnt
View attachment 31228
Inside of the case removed with outer gear

That was a hot one!