Having previous experience with a Hydraulic clutch on our 400EX, we knew that Project Raptor would have to have one also. We contacted Magura USA and obtained their HYMEC kit for the Yamaha Raptor. The complete system is part # 0120492-10, which is actually the same as the KX250 kit with the addition of a spacer for mounting.

A hydraulic clutch has many advantages over a standard mechanical clutch. The hydraulic clutch requires less lever pull than most mechanicals and the lever pull is also shorter. The hydraulic system is self-adjusting which means less maintenance and no cables to lube.

INSTALLATION First you need to get rid of that bulky factory clutch and emergency brake assembly. Make sure to pay attention where the cables run, as you will want to route the new Magura cable along the same route.

Factory assembly (missing broken lever)

Factory cable attachment

Factory Emergency brake

ProTech ATV Brake block-off

Detach the two wires from the assembly. You will need to "short" one of these back to itself and disconnect the other at the harness. This will now allow your Yamaha Raptor to start in gear. *Now would be a good time to add a ProTech ATV billet block-off cover when you remove the rear emergency brake.

Wires removed from factory assembly

Disconnect both at wiring harness. One should be taped up. The other should be plugged back into itself to short it.

Factory clutch - long and cumbersome

Magura clutch - lighter and more efficient

With the factory parts out of the way, you need to route the Magura cable, install the clutch and master cylinder on your handlebars, and mount the slave cylinder.

We had to remove the snap washer and lever, then re-attach slightly forward for proper distance from the slave cylinder.

The Magura slave cylinder is very compact and mounts in the same bracket as the factory assembly.

Mount master cylinder and place on handlebar so lever is comfortable and has clearance around switches.

Show adjustment knob and closeness to electric switches

Does it work?

Absolutely. The clutch pull is much smoother and easier than the mechanical clutch, and it is virtually maintenance free. It was nice to get rid of the bulky factory assembly at the same time. I would like to see a braided line used instead of the plastic one, though so far the plastic line is holding up just fine. The instructions were marginal but it was not hard to figure out how to install the clutch.

It is not hard to see why Cannondale includes this clutch on all of their quads. The Magura Hymec clutch makes a good addition to your sport quad.

Check the HYMEC application chart to see if Magura has one for your ATV. UPDATE (10/08/02): One of our readers has sent email to tell us about how he melted the plastic line running to the slave cylinder. You must be very careful to route this line so that it does not come in direct contact with a heat source.

Magura USA
1902 Miller Drive
Olney, IL 62450
618-395-2200
www.magura.com
moto@magura.com