HRC Power-Up Kit Install on a TR

HRC Power-Up Kit Install on a TRX450R

Materials List:

Feeler Gauges--Each cam has different specifications look at the valve clearance information for your cam of choice and you need feeler gauges in that range; my write up lists the 04/05 HRC Cam specs.
Vice Grips--shown in install pictures; others use a vice.
Zip ties.
Hot Cams shim kit-- or a local dealer that stock shims...the Hot Cams kit is great to have around.
1/4" drive metric sockets.
3/8" drive metric sockets.
Metric end wrenches.
Side cutters--to remove the zip ties with? Razor knife?
Slip-joint pliers--come in handy to work with the clamps on the fuel line.
Metric Allen wrenches.
Allen tipped sockets--Either one will work both is best!
Helper. A few of the steps involve two people unless you are a lot more coordinated and limber then I am.
3/8" Torque wrench.
Flat blade screwdrivers.
Phillips head screwdrivers.
Locktite.
Needle nose pliers.
Moly paste.
Motor oil.
Container--to mix the moly/oil 50/50 solution in.

NOTE: If there is more then one bolt holding anything on that you are removing follow this procedure. Example: There are 3 bolts holding the valve cover on, put your socket on bolt #1 and barely break it loose, then bolt #2, then bolt #3, then remove bolt #1, then #2, and finally #3. DO NOT remove #1 before you break #2 and #3 loose. If there are 4 bolts follow the same procedure using a crisscross pattern. The same goes for tightening, install all 3 bolts and hand tighten, then cut the torque spec in half and start with #1, then #2, finally #3. Then reset your torque wrench to the full amount and repeat. If the torque amount is high, like 40 ft/lbs, then start at 10, then 20, 30 and finally end at 40...Do not just cut a large amount like that in half. Use this procedure anytime there is more then 1 bolt…it may take a little longer but not in comparison to a broken bolt or stripped threads. If you have any questions regarding this process please email me.

You can start anywhere in the document you like, this is just the order I went in.

I would highly recommend you do not perform this install without the factory Honda Repair manual 61HP101.

1) Remove the seat, rear plastic, and finally the front plastic.

***Plastic removed***

2) Remove the gas tank.

a) Ensure the gas is turned off.

b) Remove the screw holding the petcock and remove the lever and fuel mark plate.

c) Remove the hose from the bottom of the tank to the carburetor, remove the 2 bolts securing the tank, the two tank straps, and lift the tank off.

3) Remove the PROTECTOR, TANK HEAT (LOWER) (the plastic piece below the tank).

*** PROTECTOR, TANK HEAT (LOWER)***

4) Loosen the hose clamp holding the white plastic snorkel and install the HRC snorkel and retighten.

5) Remove the airbox lid by unsnapping the 4 metal retainers and the two bails and install the new HRC lid. Installation of the mud flap is optional.

***HRC lid and Snorkel installed***

***Mud Flap Installed***

6) Remove the 3 bolts holding the muffler end cap on and slide out the core and old gasket. Install the new gasket and HRC end cap and tighten the bolts to:

7) Disconnect the 3-way breather joint from the crank case, air box, valve cover and replace with the HRC joint.

***This is the 3-way breather joint***

That takes care of the low hanging fruit…time to get into the good stuff.

I chose to remove my carburetor for simplicity, pics, and it was the first time to re-jet something in the last 8 years.

***NOTE*** you do not have to remove the carburetor to install the needle and main jet. You just have to loosen the clamps in front of and behind the carburetor and rotate it 90 degrees.

8) Remove the 4 screws from the top set and lift off.