High Lifter Outlaw Clutch Kit for Yamaha 600 Grizzly (98-01) - Manual (Page 2)

5. Remove the large nut (22mm) that holds the secondary clutch on. Set aside the white plastic fan blade and spacer,
noting the order they were removed. Remove the clutch and the belt from the machine. Using a 1 13/16” socket or
a large wrench loosen the large nut holding down the secondary spring retainer. ONLY TURN NUT 1/2 TURN, DO
NOT TOTALLY REMOVE 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 slowly release the pressure off the spring. Remove the
spring.
6. Remove the rest of the primary clutch off of the machine. Remove the oil drain plug from the motor; if you can
carefully drain it into a clean container you should be able to reuse it. After oil is drained remove the bolts that hold
the aluminum housing that contains the internal clutch. This is the housing that has the shaft sticking out of it that
the primary clutch sits on. Slowly remove the housing, try not to damage the gasket. If gasket is damaged you will
need to install a new one. Some oil may leak from the housing when first removed, this is normal. Note: There is
a directional bearing inside the clutch housing that could fall while removing the housing.
7. Remove the nut (27mm), some nuts are peened flat and must be straightened before they can be removed. Slide
the clutch basket off; keep track of which side faces out. Place clutch on a clean work area. Push down slightly on
the outside cover and remove the e-clips. Keeping track of which way they come off remove the three round metal
plates one at a time. This will allow you to see and change the complete spring. Remove the stock sprague 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 hole. Install the three metal plates and the e-clips. Slide the clutch basket back
onto the machine. Install the nut and torque it to 115 ft/lbs, if it was peened over be sure to peen it back to lock it
into position. If the directional bearing came out, replace the bearing on the inner Sprague clutch. The bearing is
stamped indicating which side faces out. Make sure to put the bearing on making sure the stamping is facing out, if
it did not come out when removing the housing it should be good. Install the gasket and install the aluminum
housing. Torque the housing bolts to 7.2 ft/lbs.
8. Bolt on the clutch housing and any other brackets that were removed. Push the back half of the primary clutch back
onto the shaft. Put the secondary clutch on; make sure it slides on all the way. Torque the nut to 72 ft/lbs. Thread
the bolt included in this kit into one of the threaded holes on the side of the secondary clutch. This should spread
the clutch sheaves apart. Put the belt in the clutch. 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.
9. 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 and washer. The clutch should slide all the way back
easily. If the clutch doesn’t seem to go on far enough to tighten the nut properly (it should slide all the way on to
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 farther. If the rollers seem out of place take the clutch apart and
check roller location. Install the large nut and torque it to 85 ft/lbs. Remove the bolt that was threaded into the
secondary clutch.
10. Assemble the aluminum clutch guard and carefully install the plastic clutch cover and gasket to ensure a good seal.
Install the vent lines. Put the foot rest, small plastic body piece, and the seat back on.
11. Install oil drain plug. Refill your engine oil to the proper level according to owners manual. You can reuse your oil
if it is clean and was drained into a clean container. You must use NON Friction Modified oil (stock Yamaha). DO
NOT use oils with Friction Reducing Agents, this WILL CAUSE SLIPPAGE AND DAMAGE.
12. 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.