High Lifter Outlaw Clutch Kit for Suzuki Vinson 500 (02-06) - Manual (Page 2)

6. Place the spring retainer on the work surface. Place the EPI spring in the clutch. Place the spring retainer on top of
the spring. Set the nut on top of spring retainer, using the compression tool or press slowly and carefully compress
the spring until you can start to thread the nut onto the shaft. You might need to take a punch or a screwdriver and
rotate the spring retainer so the flat spots line up properly to fully compress the spring. Once the retainer is in place
tighten the nut, remove the clutch from the press and torque the nut to 72.5 ft/lbs.
7. Remove the oil drain plug from the motor. If you can, carefully drain the oil into a clean container. You should be
able to reuse the oil.
8. Remove the rest of the primary clutch off of the machine. Remove the three Phillips head screws hold and the metal
plate that is located on the aluminum housing. Note the arrow on the plate; this will need to face toward the front
of the machine when reassembled. Loosen and remove the front and rear vent lines off of the aluminum housing.
Remove the bolts holding the aluminum clutch housing; keep track of each bolt length and location. Once all the
bolts have been removed slowly pull the cover towards you being careful not to damage the gasket. If the gasket is
damaged you will need to install a new one. Some oil may leak from the housing when first removed, this is normal.
9. Remove the nut (left handed threads usually a 24mm) holding the internal clutch on. Slide the clutch basket off;
keep track of which side faces out. Place the clutch on a clean work surface. Remove one end of each spring with a
spring tool or pliers. Push down slightly on the outside cover and remove the e-clips. Keeping track of which way
they come off remove the three metal plates one at a time. This will allow you to see and change all of the primary
springs. Install the EPI springs by inserting the spring into the outer edge first. Using a spring tool or pliers pull on
the spring and insert the end into the inner hole. Install the three inner plates and the e-clips. If the three plates
don’t seem to fit flat or correctly to install the e-clips, check to see if one of the five Spragues is sticking up. If it is
remove one end of the spring on the Sprague that is sticking up, push down and reinstall spring. Slide the clutch
back onto the machine and install nut. Note: There is a directional bearing inside the clutch housing. If it
did not come out when removing the housing it should be good. If it came out, replace the bearing on the inner
Sprague clutch. The arrow should be facing out so it points in the clockwise direction. Torque the nut to 94 ft/lbs.
Clean both gasket surfaces, install new gasket and the aluminum housing. Torque the housing bolts to 7.2 ft/lbs.
10. Install the clutch housing onto the machine. Install front and rear vent lines. Push the back half of the primary
clutch on the shaft. While holding the secondary clutch, rotate one half to open the clutch slightly and insert belt
into clutch. The belt must be stuck inside the clutch approximately 1/2” from the outside edge for proper
installation. Most belts have an arrow indicating direction of rotation. If your belt doesn’t, be sure to install it so that
you can read the part number. In either case, always run the belt the same direction as it was new. With the belt
inside the clutch slide the secondary clutch onto the rear shaft and torque nut to 83 ft/lbs.
11. Grab the primary clutch, push the inner part down with your thumbs and hold down as you pick up the clutch.
While holding the inner part of the clutch from moving, slide the primary clutch onto the shaft. This should keep the
rollers in place. Keep it pushed in until you can install the nut. The clutch should slide all the way back easily, If
the clutch doesn’t seem to go on far enough to tighten nut properly (it should slide all the way onto the edge of the
splines) you might have a roller out of place or the belt might be blocking it. If needed move the belt up and down
to see if the clutch will slide on further. If rollers seem out of place take the clutch apart and check roller location.
Install nut and torque to 83 ft/lbs.
12. Assemble the aluminum clutch cover and gasket. Install the metal foot rest bracket and plastic foot rest and foot
brake arm. Tighten bolt.
13. Install oil drain plug. Refill your engine oil to the proper lever according to owners manual. You can reuse your oil
if it was clean and was drained into a clean container. Only use manufactures recommended oil for proper engine
and clutch operation.
14. Go out and ride your machine. If the performance doesn’t seem right double check to make sure everything has
been done properly.
NOTICE: Even with this clutch kit, you should be advised that using substantial throttle when the tires are not able to
spin can cause the belt to slip and damage may occur. EPI recommends that the transmission be shifted into low
range when high load, slower speed situations are encountered. EPI is not responsible for any damage to the drive
belt or any other original equipment component.