High Lifter Outlaw Clutch Kit for Yamaha 450 Rhino (06-09) - Manual

8273 Industrial Park Road ▪ Baxter, MN 56425 ▪ (218) 829-6036 ▪ Fax (218) 829-1685
YAMAHA OUTLAW SUPER DUTY KIT INSTRUCTIONS
Model: 450 RHINO 4x4 2006-2009 (27”-28” TIRES) Part #: HLCKY450RH
Kits designed for Stock motor and stock exhaust at 0-3000 feet elevation.
THIS KIT IS NOT DESIGNED FOR USE WITH A MACHINED (OVERDRIVE) PRIMARY CLUTCH SHEAVE
ATV’s can be dangerous. EPI has no control over the use of any part. EPI expects the customer to exercise good
judgment as to the proper selection, installation, use and maintenance of any part. EPI assumes no responsibility for
damage or injury of any kind because of misuse, improper installation and improper application of any parts in any way
by any person. Contact your local dealer to schedule installation of this clutch kit if you are not a qualified ATV
mechanic.
This product is NOT to be installed on any ATV that will be used by any person under the age of 16 years
old.
TOOLS NEEDED TO INSTALL CLUTCH KIT
- Set of metric sockets up to 27mm
- Phillips and flat tip screwdrivers
- 1 13/16 socket or wrench
- Torque wrench
- Spring tool or needle nose pliers
- Clutch compression tool (EPI Part # CCT510)
- 1/2 impact wrench
- 2-3 quarts of Yamaha Motor Oil
GASKETS NEEDED TO INSTALL CLUTCH KIT
- Order gaskets from your local dealer before you install clutch kit.
- Yamaha may call some gaskets carb gaskets. These are the correct gaskets.
- Internal Clutch Housing Gasket - part # 5GH-15463-00-00
1. Remove the key from the ignition switch. Remove driver’s and passenger seats. Remove black plastic center
console between the seats. The console lifts up and off from the engine bay. Remove plastic fasteners from the
seat frame cover on the driver’s seat frame. Remove cover. Remove the angle brace on top of driver’s seat frame.
This will give adequate room for removal of the secondary clutch. Remove front and rear vent lines. Remove plastic
clutch cover, note were the wire clamps are during bolt removal.
2. Once the clutch cover has been removed take the aluminum clutch guard off. You now should be able to see the
complete primary clutch. The clutch is filled with grease and must stay that way. Do not remove any grease unless
it is on the outside of the clutch, on the inner clutch sheaves where the belt rides, or on the belt. If any grease is on
these areas it will cause belt slippage. Clean these areas with contact or brake cleaner that doesn’t leave an oily
film.
3. Remove the large nut and washer that holds the primary clutch (normally 22mm) on. Once the nut has been
removed pull the clutch off of the machine. Remove the thin cover plate and the rubber o-ring. Carefully slide the
inside plate up and out of the clutch. Do not clean off any grease unless necessary. This should reveal eight clutch
rollers.
4. Remove one roller and press the inside bushing out of it. You can usually use a 18mm/19mm or 11/16 socket and
push the bushing out by hand. If needed, set the roller on a 26mm or a 1 1/16 socket, set the smaller socket on the
inner bushing and lightly tap with a hammer to remove the inner bushing. The bushing can only be pushed in one
direction, make sure you are pushing it out the right way or damage can occur. Press in the new bushing supplied
in the kit and place the roller back in the clutch. Repeat this step for the remaining rollers. NOTE: If your kit has
two different weights, be sure to place them directly across from each other (or every other one). This
keeps the clutch in balance. Make sure you have all eight of the rollers in the proper place and position. Install
the inside plate making sure all the rollers are in the proper location. Put the rubber o-ring and the thin cover plate
back on the clutch. Place clutch out of the way and start working on the secondary clutch.
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