High Lifter Outlaw Clutch Kit for Suzuki Vinson 500 (02-06) - Manual

8273 Industrial Park Road ▪ Baxter, MN 56425 ▪ (218) 829-6036 ▪ Fax (218) 829-1685
SUZUKI OUTLAW SUPER DUTY KIT INSTRUCTIONS
Model : 500 VINSON AUTO 4x4 2002-2006 (27”-28” TIRES) Part # : HLCKS500VN
Kits designed for Stock motor and stock exhaust at 0-3000 feet elevation.
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.
Tools needed to install clutch kit
- Metric socket set
- 32 mm socket
- Torque wrench
- Spring tool or needle nose pliers
- Clutch compression tool (EPI part # CCT510)
- 1/2” impact wrench
- Suzuki oil
- Punch or spanner wrench
- Flat and Phillip tip screwdriver
Gaskets needed
- Order gaskets from you local dealer before you install clutch kit
- Internal clutch housing gasket - part # 11482-09F50
1. Remove the key from ignition. Remove the right side foot rest including the metal support bracket.
2. Remove bolt from foot brake and slide brake arm out ½ way off splined shaft. Remove the aluminum clutch cover.
Note the length of the bolts and their location.
3. Once the clutch cover is removed you should be able to see both clutches. Remove the nut (32 mm socket) that
holds the primary clutch on. Pull the clutch off the machine and place on a flat clean surface. Slide the inside plate
up and out of the clutch. 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.
5. Remove the large nut (32 mm socket) that holds the secondary clutch on. Remove the clutch and belt from the
machine. Using a spanner wrench or punch and a hammer loosen the large nut holding the secondary spring
retainer. ONLY TURN NUT 1/2 TURN - DO NOT TOTALLY REMOVE THE NUT. The nut and retainer are
under extreme pressure and can cause damage or injury if not removed properly. Using a compression
tool, (EPI part #CCT510) carefully compress the spring enough to take the pressure off the nut. Remove the nut
and slowly release the pressure off the spring. Remove the spring.
EPIperformance.com