High Lifter Outlaw Clutch Kit for Honda 400 Rancher Springs Only (03-07) - Manual

8273 Industrial Park Road ▪ Baxter, MN 56425 ▪ (218) 829-6036 ▪ Fax (218) 829-1685
HONDA OUTLAW SUPER DUTY KIT INSTRUCTIONS
Model: 400 RANCHER AT 4x4 2004-2007 Part #: HLCKH400RN-P
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
- Set of metric sockets
- 27mm socket
- Phillips and flat tip screwdrivers
- Torque wrench
- Spring tool or needle nose pliers (45 or 90 degree bent pliers work well)
- 1/2” impact wrench
- Honda motor oil
- Honda clutch tool # 07933-HB3000A
- 5mm Allen wrench
GASKETS NEEDED TO INSTALL CLUTCH KIT
- Order gaskets from your local dealer before you install clutch kit.
- Crankcase cover gasket # 11394-HM7-003
1. Remove the key from the ignition switch. Remove the left and right side lower front fender by using two flat tip
screwdrivers to pop off the plastic darts. Remove four bolts holding the plastic engine cover on the right side of the
motor.
2. 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. Loosen and remove the oil lines on the front of motor (5mm allen wrench). Note line Location for proper
assembly.
3. Remove the plastic shield for the front driveshaft by removing the two plastic darts and one bolt. Remove the right
side front inner fender well. Remove the front crankcase cover bolts; keep track of each bolt length and location.
Do not loosen or remove tension adjuster nut on crankcase cover. Slide crankcase cover off slowly. Watch for
internal parts inside the cover on the left side of the machine so you know how they go back on. You may need to
loosen the rubber boot on the front shaft for enough clearance to slide cover off. Watch for a washer lying inside the
cover when removed, it will normally stick to the cover or will remain sitting on the small shaft with the shift lever.
4. Using an impact wrench and 27mm socket remove the nut and washer in the center of the clutch. Using the Honda
tool # 07933-HB3000A, thread the large part of the tool into the center of the clutch. Tighten the center bolt on the
tool while holding the large part of the tool with a wrench. This will pull the clutch and outer housing off the
machine. There is a directional bearing in the clutch housing, if bearing is removed or falls out make sure arrow on
the bearing is pointing in the clockwise direction as you face the bearing when placed in the housing. This bearing
does not need to be removed. Slide clutch out of housing and place on a clean work surface.
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