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

[CumminsPusher]

@HondaTech Since you have the book and do many of these is there anything you'd like to add here or suggestions you'd like to make? I tried using common tools that everyone has access to and we did as good we could on pictures and explaining the process. Love some factory input if you would.

 

[Admin]

 

[AKRider]

View attachment 21311

Lets talk CLUTCH REPLACEMENT!
The 2016 Honda Pioneer 1000 seems to be getting a reputation for having clutch failures and it has been common perception that Honda was taking care of these issues as they come up for all its loyal riders. WRONG!

Lets say if you are stock and haven't drove through a puddle of water 10" or more, then you have a fairly good chance the Honda will approve your replacement. But if you have modified your Pioneer outside "there liking"... well.... You best just read up on the below!

But... Not to worry. For less then $350 and a few hours time you can be back on the trial!


If you can replace an alternator or water pump in your car/truck then you are more then capable of completing this clutch replacement!

Time needed!

• Stealership = 7 + Hour$$$$$.
• Novice mechanic = 3-4 hours.
• Home mechanic = 3 hours.
• Back yard mechanic = 2 hours.

Parts list.

• CLUTCH PACK - 22500-HL4-003 - $260 (need 1)
• GASKET, CLUTCH COVER - 11397-HL4-003 - $8.25 (need 1)
• O-RING (35X2.2) - 91302-RGC-003 - $1.52 (need 2)
• Honda GN4 10W-30 Motorcycle Oil - Gallon (need 2)
• Pack of your favorite beverage! (just get 1)

Oil Filters and Oil.
See: Honda Pioneer 1000 Oil Change Guide!

• Honda GN4 10W-30 Motorcycle Oil - Gallon (need 2 gallons)
• OIL Filter Part Number - 15412-HP7-A01 (need 1)
• DCT Filter Part Number - 15412-MGS-D21 (need 1)

The below is from a 2016 Honda Pioneer 1000-5 Deluxe.

How I missed this writeup I don't know, but this is freaking AWESOME! Thank you @CumminsPusher. After reading through this I now believe I have the confidence to install the IGR myself. Now I just need to wait for my bank account to build up a little... lol

 

[CumminsPusher]

It's not bad at all don't even hesitate it's a great design plenty of room and no specialty tools. I'm now under an hour lol.

 

[AKRider]

@Hondasxs What do you think about making this a sticky thread? It definitely ranks up there with the best and most useful.

 

[AKRider]

It's not bad at all don't even hesitate it's a great design plenty of room and no specialty tools. I'm now under an hour lol.

How many times have you done it?

 

[CumminsPusher]

A few. Two sets of clutches but the second new set was totally my fault thought I was stuck but ebrake was set , oops. But I opened it back up for better pictures and both times they went out I flipped the r,1,3,5 to the 2,4,6 sides so I'd have reverse and first if that makes sense. I didn't let slipping clutches ever slow us down. Actually thought they were going again but it's nice and solid with 750 on the new set I'm back to happy. Being careful with reverse and trying to bump up speed in the climbs I expect better life this round!


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[AKRider]

A few. Two sets of clutches but the second new set was totally my fault thought I was stuck but ebrake was set , oops. But I opened it back up for pictures and both times they went out I flipped the r,1,3,5 to the 2,4,6 sides so I'd have reverse and first if that makes sense. I didn't let slipping clutches ever slow us down. I actually thought they were going again but it's nice and solid with 750 on the new set I'm back to happy.


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LOL... I can see that. Most of my riding is low and slow, manually shifting and keeping the RPM's up. As I've told you before, I'm surprised I haven't burned up mine with a couple of the boneheaded things I've done, but I didn't know any better when I did them. I might just get a set on order so I have them. I know when I do the IGR my wife will be right there making sure I don't screw it up... lol. She's really good about catching the little things that I sometimes overlook.

 

[CumminsPusher]

LOL... I can see that. Most of my riding is low and slow, manually shifting and keeping the RPM's up. As I've told you before, I'm surprised I haven't burned up mine with a couple of the boneheaded things I've done, but I didn't know any better when I did them. I might just get a set on order so I have them. I know when I do the IGR my wife will be right there making sure I don't screw it up... lol. She's really good about catching the little things that I sometimes overlook.

I'm surprised you haven't had problems and a couple others. But then some do that shouldn't it's random.
It's really easy AK. It sucks to have to replace them but it's not a huge deal. The only hard part is getting the basket back in nice and smooth. If the cover doesn't sit flush without bolts then you have to pull the basket back out and reinstall.
I'd get the IGR but speed sometimes is important I'd rather replace clutches occasionally then rev it super high when we do hit pavement and need to do the speed limit. Like I said though once I decide to up the tire size I'll 100% get the setup. Our speeds sometimes get very low in some areas just can't run faster so we'd be trashing clutches without that. 1st and especially reverse could have been lower especially for a "utility " sxs.


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[Smitty335]

I'm surprised you haven't had problems and a couple others. But then some do that shouldn't it's random.
It's really easy AK. It sucks to have to replace them but it's not a huge deal. The only hard part is getting the basket back in nice and smooth. If the cover doesn't sit flush without bolts then you have to pull the basket back out and reinstall.
I'd get the IGR but speed sometimes is important I'd rather replace clutches occasionally then rev it super high when we do hit pavement and need to do the speed limit. Like I said though once I decide to up the tire size I'll 100% get the setup. Our speeds sometimes get very low in some areas just can't run faster so we'd be trashing clutches without that. 1st and especially reverse could have been lower especially for a "utility " sxs.


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The Dealer replaced both clutch packs, chamfered oil pressure relief valves and cleaned oil pick up screen under warranty. At 185 miles. I under stand cleaning the screen, but chamfering the oil pressure relief valves? What ever they did to it made a big difference in the noise it makes when going through the gears. Chamfering oil relief valves?

 

[CumminsPusher]

The Dealer replaced both clutch packs, chamfered oil pressure relief valves and cleaned oil pick up screen under warranty. At 185 miles. I under stand cleaning the screen, but chamfering the oil pressure relief valves? What ever they did to it made a big difference in the noise it makes when going through the gears. Chamfering oil relief valves?

That's good they took care of you! Too bad it seemed to need all of that but now that you've got it back go enjoy her some

 

[Smitty335]

That's good they took care of you! Too bad it seemed to need all of that but now that you've got it back go enjoy her some

When I first got mine it was very noisy shifting even in the yard, now it clicks instead of clunking?

 

[Smitty335]

CP Thank you for the post on replacing clutch assemblies. That is awesome!!!!!!!!!!!!

 

[joeymt33]

When I first got mine it was very noisy shifting even in the yard, now it clicks instead of clunking?

That's usually what everyone says after the first oil change. I'm sure they put new oil back in it.

Sounds like it's all good for you now.

 

[dale5740]

Pre assembled. Ready to go

thanks cp for all this and everyone involved makes me not want to buy extended warranty!! Kinda like doing clutches on anything else!!

 

[Smitty335]

That's usually what everyone says after the first oil change. I'm sure they put new oil back in it.

Sounds like it's all good for you now.

I was going on my second oil change when the failure happened

 

[ghost]

How I missed this writeup I don't know, but this is freaking AWESOME! Thank you @CumminsPusher. After reading through this I now believe I have the confidence to install the IGR myself. Now I just need to wait for my bank account to build up a little... lol

That's exactly what I was thinking !
I was reading the service manual and scooterChris's IGR thread but still felt a bit uneasy about digging into it - till I read this. Also great if I ever trash my clutches - dont want to go back to stealership.

Awesome writeup - fills in lots of gaps from the service manual.

 

[Eltobgi]

@CumminsPusher You make this statement...

On the end of the transmission shaft there are two plastic o rings that have to be replaced. Take them off carefully (in case you bung a new one up later) but don't replace at this point!

My question is where do these plastic o rings come from because i didn't see a part number for them.

 

[CumminsPusher]

@CumminsPusher You make this statement...

On the end of the transmission shaft there are two plastic o rings that have to be replaced. Take them off carefully (in case you bung a new one up later) but don't replace at this point!

My question is where do these plastic o rings come from because i didn't see a part number for them.

My apology I will update! As long as you're careful and pull these before the clutch basket they should be ok. The only issue with these is where they overlap they get thin and easy to bung up.

 

[Eltobgi]

@CumminsPusher , does this look like the right part number

 

[Montecresto]

View attachment 21311

Lets talk CLUTCH REPLACEMENT!
The 2016 Honda Pioneer 1000 seems to be getting a reputation for having clutch failures and it has been common perception that Honda was taking care of these issues as they come up for all its loyal riders. WRONG!

Lets say if you are stock and haven't drove through a puddle of water 10" or more, then you have a fairly good chance the Honda will approve your replacement. But if you have modified your Pioneer outside "there liking"... well.... You best just read up on the below!

But... Not to worry. For less then $350 and a few hours time you can be back on the trial!


If you can replace an alternator or water pump in your car/truck then you are more then capable of completing this clutch replacement!

Time needed!

• Stealership = 7 + Hour$$$$$.
• Novice mechanic = 3-4 hours.
• Home mechanic = 3 hours.
• Back yard mechanic = 2 hours.

Parts list.

• CLUTCH PACK - 22500-HL4-003 - $260 (need 1)
• GASKET, CLUTCH COVER - 11397-HL4-003 - $8.25 (need 1)
• O-RING (35X2.2) - 91302-RGC-003 - $1.52 (need 2)
• Honda GN4 10W-30 Motorcycle Oil - Gallon (need 2)
• Pack of your favorite beverage! (just get 1)

Oil Filters and Oil.
See: Honda Pioneer 1000 Oil Change Guide!

• Honda GN4 10W-30 Motorcycle Oil - Gallon (need 2 gallons)
• OIL Filter Part Number - 15412-HP7-A01 (need 1)
• DCT Filter Part Number - 15412-MGS-D21 (need 1)

The below is from a 2016 Honda Pioneer 1000-5 Deluxe.

I bought a Honda so I'm not going to have to replace clutches.