P1000 Honda Pioneer 1000 Clutch Replacement - A How To Guide!

[Officer30]

The clutches are fully seated, but the gears on the left are not flush yet. Is there a special way to twist the gears to get the anti rattle mechanism in?

 

[Admin]

 

[Officer30]

The clutches are fully seated, but the gears on the left are not flush yet. Is there a special way to twist the gears to get the anti rattle mechanism in?

Figured it out the. Ack washer was slidding down just enough stop stop it. A little grease to hold the washer and it sled on.

 

[Officer30]

Thanks for this article, everything worked as you stated the only issue I had was the back washer slid down had to put grease on it to keep it in place

 

[1meanchevy]

Thanks for the article , i was about ready to send my Pioneer out to pasture and buy a newer one , but this clutch swap changed the game. Next time I'll teplace the cover if I ever find a good write up on a swap.

 

[WRFP399]

I just went through this process to replace the R,1, 3, 5 clutch on my 2017. Took me a few days but I split it up into hour or two sessions. Day one was just washing everything down. Day two was removal of body panels to make life easier and rewashing now that I had additional access. Day three was tear down. Day four was putting the new clutch pack on the input shaft and day 5 was reassembly.

I found that Honda sells a Clutch Cover Gasket/Rebuild Kit which includes all the gaskets, o rings and strainers needed for a full clutch cover tear down and cleaning. It is Honda Part Number 06113-HL4-307.

Miles on my machine are 950ish. Previous owner must have run that clutch down as it's been kinda weird since day one with me. It now goes in and out a gear so smooth, starts and stops smooth and gear shifts are amazing.

 

[Remington]

I just went through this process to replace the R,1, 3, 5 clutch. Took me a few days but I split it up into hour or two sessions. Day one was just washing everything down. Day two was removal of body panels to make life easier and rewashing now that I had additional access. Day three was tear down. Day four was putting the new clutch pack on the I put shaft and day 5 was reassembly.

I found that Honda sells a Clutch Cover Gasket/rebuild kit which includes all the gaskets, o rings and strainers needed for a full clutch cover tear down and cleaning. It is Honda Part Number 06113-HL4-307.

Miles on my machine are 950ish. Previous owner must have run that clutch down as it's been kinda weird since day one with me. It goes in and out a gear so smooth, starts and stops smooth and gear shifts are amazing.

View attachment 439921

What year is your rig?

 

[WRFP399]

Initial tear down.

 

[WRFP399]

Here is what the oil looked like...not horrible. Some material in there.

Also this is the old clutch pack as seen when the cover is removed. Minor blueing on the basket but the steel plates are very brown.

 

[WRFP399]

The new clutch pack next to the old. Note the height difference from the worn friction material.

 

[WRFP399]

Opened up the valve body to clean per the service manual. Only found minor black "sludge" in the low lying areas. Nothing clogged, blocked or otherwise non functional. Wasn't needed but it's peace of mind at this point. Spent significant amounts of time with alcohol and a tooth brush cleaning mud/dirt from all electrical connections. Sprayed them down with silicone spray prior to reassembly.

 

[WRFP399]

The new pack, waiting for it's cover followed by completed reassembly and initial test start.

 

[Remington]

Year?

 

[DRZRon1]

Outstanding work and glad it was seamless and u r as good as new

May I ask why does the motor have what looks like a powder coating of mud color?
I’m tarting out right now

 

[WRFP399]

Lots of mud and deep water up here in AK. The aluminum is basically stained from it for lack of a better term.

 

[Remington]

Miles on my machine are 950ish.

Ok One more time, What year is your rig? AKA SXS, Honda P1K5?
Just curious with the low miles and these issues. Im sure many would like to know this as well. Sorry

 

[tjoreo]

Ok One more time, What year is your rig? AKA SXS, Honda P1K5?
Just curious with the low miles and these issues. Im sure many would like to know this as well. Sorry

In his original post it says his machine is a 2017 but from your reply it looks like he has edited it. That's what I was guessing as that was the year of the blue panels as they were what I was thinking about changing too from my Yellow 2018 panels. His pictures give a better idea of how everything goes together just in case I have to tackle this some day. Thanks for the pics @WRFP399

 

[Remington]

In his original post it says his machine is a 2017

Yeah thats why why i wanted to know. Wonder if the clutch campaign was ever done to it before the clutches were smoked?
Would be very interesting to know!
People like to leave us hanging like Epstine all the time lol

 

[tjoreo]

Yeah thats why why i wanted to know. Wonder if the clutch campaign was ever done to it before the clutches were smoked?
Would be very interesting to know!
People like to leave us hanging like Epstine all the time lol

It's tough to see through all mud and stained motor but it looks like it has the "rounded bump" of the new clutch cover. My big computer screen at works shows it. It looks like it has a tough life either way. Not much mud and deep water here in the desert of idaho. Mine is just dusty.

 

[WRFP399]

I apologize for any delays in my responses. I don't spend my life online, and my time is often spent at work, with family, or outdoors where there is no service.

Yes the cover is the updated cover. It was already installed when I purchased the machine. A clutch can be burned for numerous reasons and the primary is someone not using the machine properly. I can only guess the prior owner ran the machine hard. All it takes it to get it stuck and try to power out in high range, tow another machine through rough terrain in high range, etc to overwork the clutch. When I got it I had no base line as to 'proper' shifting and clutch work. It seemed to be okay but having a new clutch now I realize it was always just a bit 'off'.

This season I was pushing my Pioneer pretty hard. I was opening up some old trails in a mountainous and muddy area, and spent most of the time in low range 4WD diff lock. There were some very steep, very long inclines that the machine had to get up. I think this is what finally finished off the clutch, although I didn't notice anything unusual while performing the ascents. I made the ascents about three or four times in total. It wasn't until I got home, washed the machine, and it cooled down overnight that I noticed excessive clutch slippage when moving it to the garage.

It is about 1060 feet long with an elevation gain of about 400 feet which is about a 35-40% grade.

 

[tjoreo]

I apologize for any delays in my responses. I don't spend my life online, and my time is often spent at work, with family, or outdoors where there is no service.

Yes the cover is the updated cover. It was already installed when I purchased the machine. A clutch can be burned for numerous reasons and the primary is someone not using the machine properly. I can only guess the prior owner ran the machine hard. All it takes it to get it stuck and try to power out in high range, tow another machine through rough terrain in high range, etc to overwork the clutch. When I got it I had no base line as to 'proper' shifting and clutch work. It seemed to be okay but having a new clutch now I realize it was always just a bit 'off'.

The updated clutch cover was already installed on my machine when I bought it. The clutch can be burned for many reasons, and the main one is improper use of the machine. The previous owner must have run the machine hard, because it only takes getting the machine stuck and trying to power out in high range, or towing another machine through rough terrain in high range, to overwork the clutch. When I got the machine, I had no baseline for "proper" shifting and clutch work. The clutch seemed to be okay, but now that I have a new clutch, I realize that it was always a bit "off."

This season I was pushing my Pioneer pretty hard. I was opening up some old trails in a mountainous and muddy area, and spent most of the time in low range 4WD diff lock. There were some very steep, very long inclines that the machine had to get up. I think this is what finally finished off the clutch, although I didn't notice anything unusual while performing the ascents. I made the ascents about three or four times in total. It wasn't until I got home, washed the machine, and it cooled down overnight that I noticed excessive clutch slippage when moving it to the garage.

It is about 1060 feet long with an elevation gain of about 400 feet which is about a 35-40% grade.

View attachment 440444

View attachment 440445

Didn't mean to cause any ill fillings on the condition of the machine. Everyone has a different environment that they ride in and mine has only seen hot dry dusty roads. I sure wish I had places like you to ride. Like you said you didn't have any feedback on the life of the clutches as it was a new to you machine. There were quite a few early models with the old cover that were burning up clutches due to lack of oiling. The updated cover has helped, but there is still a few instances where clutches have burnt up. I'm glad you got it back up and running and hopefully you can get out and enjoy more adventures with your family. Thanks for the repair pics and the adventure pics and videos. Have a good day.