High Lifter Outlaw Clutch Kit for Arctic Cat 400i Auto 2x4_4x4 (03-08) - Manual

8273 Industrial Park Road ▪ Baxter, MN 56425 ▪ (218) 829-6036 ▪ Fax (218) 829-1685
ARCTIC CAT OUTLAW SUPER DUTY KIT INSTRUCTIONS
Model: 400 I AUTO 2x4/4x4 2003-2005 (27”-28” TIRES) Part #: HLCKA400AT
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 years.
TOOLS NEEDED TO INSTALL CLUTCH KIT
- metric socket set
- 24mm and 27mm sockets
- torque wrench
- spring tool or needle nose pliers
- clutch compression tool or shop press (EPI part # CCT510)
- 1/2” impact wrench
- Arctic Cat oil
- punch or spanner wrench
- #2 and #3 phillips screwdrivers
- 10mm wrench
- T30 torx bit
GASKETS NEEDED
- Order gaskets from your local dealer before you install clutch kit
- Internal clutch housing gasket -part # 3402-589
1. Remove the key from the ignition switch. Remove the brake sensor wire next to the right rear tire by unplugging it.
Remove the right side foot rest and slide it backwards to release the brake cable.
2. Remove the aluminum clutch cover. You will need to remove the front and rear clutch housing vents. Note the
length of the bolts and their location. Once the cover is removed you should be able to see both clutches. Remove
the nut (27mm) that holds the primary (front) clutch on. Pull the clutch off the machine and remove the center
shaft. Place the clutch on a flat clean surface, sheave side down.
3. Remove the large nut (27mm) that holds the secondary (rear) clutch on. Remove the clutch 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 (available
through EPI) or a press, 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.
4. Put the EPI spring in the clutch. Place the spring retainer on top of the spring. Set the nut on top of the spring
retainer, using the compression tool (EPI part #CCT510) 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
clutch from press and torque nut to 72 ft/lbs.
5. 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.
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