Dalton Clutch Kit Install - Can-Am Renegade / Outlander 800R

1Bad1000Xxc · Sep 30, 2009

<img border="0" src="http://atvtorture.com/forums/images/daltonouty/DI%20title%20header%20Mod%201.gif" width="514" height="67">Dalton Clutch Kit Installation - 2009 Can-Am Renegade 800Installation Details: Below we will detail for you the installation of the Dalton Clutch on our Can-Am Renegade 800R. This installation procedure is the same for the Can-Am Outloander 800R although the part numbers are different due to the weight difference in the two machines and the springs being different between the two kits. Part Numbers: Can-Am Renegade 800R: DBO 800 R Can-Am Outlander 800R kit: DBO 800 Installation options: From Dalton, the Renegade and Outlander kits come with 3 weights, and 2 sets of 3 differently weighing rivets that can be inserted into the weights depending on your setup and altitude. For our installation, we are doing this procedure on a 2009 Renegade 800-X that is running 25" tires at an altitude of 800ft. above sea level. So, we will not need to add the additional weight of either of the rivet sets. however, when we get to that point of the installation, we will detail what would require you adding the rivets and how to determine which weight rivets you would use.What is provided: 
<img border="0" src="http://atvtorture.com/reviews/dalton/thumbnails/IMG_6104.jpg" width="350" height="233" align="right">The kit comes with the following:
<ul><li>(1) Dalton Green/Yellow Primary clutch spring (Part #: DPPS - G/Y)</li><li>(3) Dalton adjustable mass flyweights/levers (Part #: DB34-8A)</li><li>(1) Package of aluminum rivets (Part #: DFRA)</li><li>(1) Package of steel rivets (Part #: DFRL)</li></ul>
 Tools Required:<ul><li>T25 torx</li><li>8mm socket and/or wrench</li><li>19mm socket on an impact wrench or pull-handle</li></ul>Disassembly Procedure:We start our instruction with the side cover already having been removed from the quad. If you are doing this on your own, we will give you enough credit to be able to safely remove the 8-10 screws that hold it on without us providing detailed instructions and pictures of that procedure for you. Those screws can be removed with either a 8mm nut driver or a T25 Torx. We actually used a 8mm nut driver on our drill for speed and simplicity.
NOTE: The side cover CAN be removed with the floorboard in tact. There is one screw underneath the side cover and one to the rear underneath it that can be a little tricky to get to but it is still easily doable with the floorboard in.The image below is the clutch as you will see it with the side cover removed.<a target="_blank" href="http://atvtorture.com/reviews/dalton/images/IMG_6099.jpg"><img border="0" src="http://atvtorture.com/reviews/dalton/thumbnails/IMG_6099.jpg" width="350" height="233"></a> (click to enlarge)To begin the project, you will need to remove the OUTER HALF ONLY of the PRIMARY clutch. We chose to use an impact wrench since we had an air compressor in our shop. If you do not have an air compressor, you can use a pull-handle or torque wrench with an 18mm socket on it. Unscrew the bolt counter-clockwise. As you begin to loosen the bolt, you may notice the outer half of the primary clutch begin to move outward. If you do not, you can lightly tap it with a rubber hammer to help break it loose. Because it is on a tapered shaft, it could be stuck and require that to allow it to be removed freely..Once the bolt has been completely loosened, the outer primary clutch half can be set aside for a few minutes. Now you will have exposed the large primary clutch spring and just behind it a spring retainer cup. You can remove the primary spring but leave the cup in place. This is what you should now see:<a href="http://atvtorture.com/reviews/dalton/images/IMG_6100.jpg" target="_blank"><img border="0" src="http://atvtorture.com/reviews/dalton/thumbnails/IMG_6100.jpg" width="350" height="233"></a> <a href="http://atvtorture.com/reviews/dalton/images/IMG_6101.jpg" target="_blank"><img border="0" src="http://atvtorture.com/reviews/dalton/thumbnails/IMG_6101.jpg" width="350" height="233"></a>
NOTE: Do NOT attempt to remove or pull outward on the inner primary clutch half as there are 2 small springs between it and the shaft, just behind the primary spring retainer cup that may shoot out never to be found again. For this installation, we will not be removing the inner half so just leave it alone.Place the outer have that has now been removed on a work bench for easy access and we will begin the disassembly process.
With the clutch laying flat on your workbench grab the center of it and lift upward to separate it and expose the guts. Once you have pulled it apart, you will have the following: (We have identified the components of the primary in this image so you may want to click it to see a larger version of it.)
<a href="http://atvtorture.com/reviews/dalton/images/IMG_6105.jpg" target="_blank"><img border="0" src="http://atvtorture.com/reviews/dalton/thumbnails/IMG_6105.jpg" width="350" height="233"></a>Now that we have the clutch apart and all parts identified, we need to remove 3 of the stock weights to prepare to install the Dalton weights. Because the Dalton kit comes with 3 weights, and because we must position them so that the clutch remains balanced, we will be replacing every OTHER stock weight with a Dalton weight. In the image below, you can see which ones we will be replacing.<a href="http://atvtorture.com/reviews/dalton/images/IMG_6106.jpg" target="_blank"><img border="0" src="http://atvtorture.com/reviews/dalton/thumbnails/IMG_6106.jpg" width="350" height="251"></a>Notice in the image below that there is a bolt that goes through the clutch with a lock nut on the opposite side that holds the weight in place. Once you remove the nut and bolt and begin to remove the weight, you will see that there is a shim on each side of the weight. Be sure not to lose the shims and re-insert them with the new weight.<a href="http://atvtorture.com/reviews/dalton/images/IMG_6109.jpg" target="_blank"><img border="0" src="http://atvtorture.com/reviews/dalton/thumbnails/IMG_6109.jpg" width="350" height="233"></a> <a href="http://atvtorture.com/reviews/dalton/images/IMG_6111.jpg" target="_blank"><img border="0" src="http://atvtorture.com/reviews/dalton/thumbnails/IMG_6111.jpg" width="350" height="233"></a>Once you remove and replace the 3 appropriate stock weights with the 3 Dalton weights, being very sure you put the small shims where they originally were, reinsert the nut and securely tighten the nut to it for all 3 weights. The finished product should look like this:<a href="http://atvtorture.com/reviews/dalton/images/IMG_6112.jpg" target="_blank"><img border="0" src="http://atvtorture.com/reviews/dalton/thumbnails/IMG_6112.jpg" width="350" height="233"></a>At this point, you will need to determine if for your application, you need to use any of the rivets that Dalton provided with the kit. Below are the circumstances by which you would determine if the additional weight of the rivets are needed for your setup and which ones to use if so:
<blockquote>Setup #1: stock ATV with stock diameter tires being ridden at 0-4500 feet of elevation. This also applies when light mods have been done like exhaust, filter or airbox mods. If this fits your application, you would insert one of the gold/steel rivets
(3.6grams/each) in each of the clutch weights in the remaining hole of it.Setup #2: Heavier aftermarket tires that are (27" or larger) OR you are running 26" tires and riding above a 4500 foot elevation - For this setup, you do not use any rivets in the weights at all.Setup #3: Stock tires riding at 4500-6500 feet of elevation OR 26" tires riding at 0-4500 feet of elevation - For this setup, you would insert one of the silver/aluminum rivets (.6grams/each) in each of the clutch weights in the remaining hole of it.NOTES: Anyone riding at an elevation above 6500 feet should use setup #2 no matter what size tire they are running.Additionally, should it be recommended that you install the rivets into your weights, when doing so, you need to use an industrial vice to squeeze the rivet once it is inserted. This will expand the exposed end of the rivet to press it into the weight. If you don't have a strong enough vice, we found you can use a heavy mallet to hit it until it has mushroomed the end of the rivet. Just be sure to have the weight and rivet sitting flat on a hard surface when using the mallet technique.
</blockquote>Once the need for additional weight by use of the provided rivets is determined, we can put things back together.Moving right along, you must now slide the top portion of the clutch back down inside the lower portion that we have been working on. HOWEVER, you may remember from parts identification image previously that we noted "sliders" in that image. These are the little round disks, smaller in diameter than a dime, that help the clutch glide smoothly up and down within itself. When you separated the top part of the clutch from the bottom part, most likely a few of these dropped out since nothing holds them in their respective holes. So, you must be sure you get all of them back in place prior to pressing the this clutch have back together. See the image below to better understand.<a href="http://atvtorture.com/reviews/dalton/images/IMG_6113.jpg" target="_blank"><img border="0" src="http://atvtorture.com/reviews/dalton/thumbnails/IMG_6113.jpg" width="350" height="233"></a> <a href="http://atvtorture.com/reviews/dalton/images/IMG_6114.jpg" target="_blank"><img border="0" src="http://atvtorture.com/reviews/dalton/thumbnails/IMG_6114.jpg" width="350" height="233"></a>Alright, now that you have gotten it back together, it is now time to put it back on the quad. But, we must first put the new Dalton Green/Yellow spring on the primary shaft, making sure it is seated in the retaining cup. Here is what you should have just before sliding the clutch half back on. <a href="http://atvtorture.com/reviews/dalton/images/IMG_6116.jpg" target="_blank"><img border="0" src="http://atvtorture.com/reviews/dalton/thumbnails/IMG_6116.jpg" width="350" height="233"></a>With the belt still in place, slide the clutch half back on the primary shaft. Once you have it in place, re-insert the bolt being sure to have the tick washer to the outside and the thin shim underneath. This will position the thin shim between the washer and the clutch itself like so:<a href="http://atvtorture.com/reviews/dalton/images/IMG_6117.jpg" target="_blank"><img border="0" src="http://atvtorture.com/reviews/dalton/thumbnails/IMG_6117.jpg" width="350" height="233"></a> <a href="http://atvtorture.com/reviews/dalton/images/IMG_6118.jpg" target="_blank"><img border="0" src="http://atvtorture.com/reviews/dalton/thumbnails/IMG_6118.jpg" width="350" height="233"></a>Tighten the main bolt down to the service manual specs. I believe it is 74 ft. lbs but you should confirm in your service manual for precautionary measure.Reinstall your side cover and the installation is complete.For more information contact<a onclick="urchinTracker ('/outgoing/http_daltonindustries_com_');" target="_blank" style="color: #FFC600" href="http://daltonindustries.com/">Dalton</a> Industries. <a onclick="urchinTracker ('/outgoing/http_daltonindustries_com_');" target="_blank" style="color: #FFC600" href="http://daltonindustries.com/">Dalton</a> Industries Limited 355 Vimy Road, Truro, Nova Scotia B2N 4K2 CanadaPhone: (902)-897-3333 Fax: (902)-897-6254 Email:<a style="color: #FFC600" href="mailto:[email protected]">[email protected]</a>

Dalton Clutch Kit Install - Can-Am Renegade / Outlander 800R

1Bad1000Xxc

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