High Lifter Outlaw Clutch Kit for Polaris 850 Sportsman XP EFI 4x4 (09-10) - Manual (Page 2)

5. It is a good idea to clean your clutches. Using a clean rag and a contact/brake cleaner that DOES NOT leave an oily
film or residue clean all areas of the clutch except on the bushings. Cleaning the clutch bushings with a cleaning
solvent can cause premature wear. This applies to both clutches.
6. Install the RED colored primary spring. Make sure the spring fits flat into the clutch at both ends. Install the cover
plate making sure the “X” lines up. Tighten the six outside cover bolts evenly so the cover goes on straight to
prevent bushing damage. After riding your machine, if you would like HIGHER engagement than where this kit
engages, you can install the ORANGE colored spring. This spring will RAISE your engagement 3-400 RPMs. If
your kit only has one primary spring you can order this optional spring through EPI.
7. Remove the secondary clutch by removing the center clutch bolt and sliding it off the shaft. On the new XP models
this is another tricky maneuver, there is limited space to get this clutch off the shaft. We find that tipping the clutch
face upwards as it pivots off the shaft helps get it both off and back on the shaft. The breather vent above it has
some flex so don’t be afraid to muscle it a bit. When the clutch does come off pay attention to the shims behind the
clutch on the shaft. These shims effect the clutch alignment, if they slide off the shaft be sure to put them back on.
8. Place the clutch face down so the four torx bolts / helix are facing up. Remove the four torx bolts. Pull up on the
helix. Note the position of the two rollers. Tighten the CCT510 compression tool in a vise (or can be drilled and
mounted to work bench). Thread one nut approximately 3/4 of the way down the threaded rod and then add
washer. Slide clutch over threaded rod putting the helix side facing up. Slide the collar, washer and the nut on.
Tighten the top nut down until there is slight pressure on the spring retainer allowing you to remove snap ring.
Remove snap ring with snap ring pliers. Slowly loosen the top nut on threaded rod allowing the spring to slowly
expand. If you run out of threads before all of the tension is off the spring lower the bottom nut to give you more
space. Remove clutch from tool. Install the EPI GREEN secondary spring. To install the spring, slide clutch on
threaded rod. Place spring in clutch, place spring retainer and snap ring on top of spring and add the washer and
nut. Tighten nut until spring retainer is down far enough to install snap ring. The spring retainer will only install on
the splines one way. If you look closely there is one extra wide spline that must match up in order for the retainer
to mesh and install. Marking these points with a marker can help during reassembly. Install snap ring and remove
clutch from tool. Install the EPI helix into clutch. Make sure that when you push the helix into the clutch you do
not damage the two plastic rollers. Install the four torx bolts. If needed, you can rotate the clutch in either
direction to align the torx bolts. Push the helix down. Tighten the four torx bolts to 42-52 in/lbs. IMPORTANT:
You must use Loctite on the helix retaining torx bolts. Failure to use Loctite on reassembly may result in
the bolts loosening and backing out while riding.
9. First install the secondary clutch back on the machine. Again, try tipping the face of the clutch upwards to make
this easier. Install the clutch retaining bolt and tighten to 15 ft/lbs. Loop the belt over the secondary clutch with
the numbers reading left to right and either squeeze the belt or pull down on it to slightly spread the clutch sheaves.
You need to do this to have enough belt slack to install the primary clutch. Place the primary clutch through the belt
and on the crankshaft. Torque the primary clutch bolt to 45-47 ft/lbs. With the transmission in neutral, spin the
clutches to backshift the belt out to its normal idle position.
10. Install the plastic clutch cover making sure it seals properly. Reinstall the portion of frame you removed, the skid
plate and rear wheel. You’re ready to ride!
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.