High Lifter Outlaw Super Duty Extreme Clutch Kit for Polaris 800 Sportsman EFI 4x4 w_Deluxe EBS (07) - Manual

8273 Industrial Park Road ▪ Baxter, MN 56425 ▪ (218) 829-6036 ▪ Fax (218) 829-1685
POLARIS OUTLAW SUPER DUTY EXTREME KIT INSTRUCTIONS
Model : 800 SPORTSMAN EFI 4x4 2005-2006 (29.5” TIRES) Part # : HLCKP800FI-SX
800 SPORTSMAN EFI STD 4x4 2007 (W/EBS) (29.5” TIRES)
800 SPORTSMAN EFI DELUXE 4x4 2007 (EBS) (29.5” TIRES)
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.
TOOLS NEEDED TO INSTALL CLUTCH KIT
- 3/8, 7/16, 1/2 socket and wrench
- 5/8 socket
- Torque wrench
- Snap ring pliers
- Phillips screwdriver
- Side cutters
- 1/8 Allen wrench
- # 25 Torx wrench
- Primary Clutch Puller (EPI part # PCP-1)
- Clutch Compression Tool (EPI part #CCT510)
ENGAGEMENT
- 17-1,800 RPMs
1. Remove the key from the ignition. Remove the left side foot rest by unbolting it from the fenders and frame.
Remove the zip ties or clamps on the vent hose coming from the top of the clutch cover. On some models you
might have to remove the seat and the left side body panel between the front and rear fenders to gain access to the
vent tube. Be careful not to damage the rubber boot when cutting the zip ties.
2. Remove the clutch cover bolts; note the length of the bolts and their location. Some models might have a little
metal clamp at the rear of the cover that needs to be removed, simply take a flat tipped screw driver and pry the
clamp off. Save the clamp because you will need to reuse it. Remove cover slowly being careful not to damage the
gasket.
3. EPI found it easiest to remove both clutches and the belt at the same time but it is not required to install kit. If you
plan on removing both clutches remove the secondary (rear) clutch bolt (1/2” wrench or socket) and temporarily
leave clutch and belt on the machine. If you are NOT removing both clutches remove the belt. You can remove belt
by squeezing the belt together between the two clutches, this will allow enough slack in the belt to remove the belt.
The primary (front) clutch is pressed onto the crankshaft of the motor. Removal of the clutch is not required but
does make the job much easier. To remove the clutch a special clutch puller is needed, this tool is available through
EPI (part # PCP-1). Notice the “X” marked on the outside cover of the clutch, on the spider, and on the moveable
sheave. These are alignment marks from the factory and must line up when you reassemble the clutch. If you are
not removing the clutch see next step. To remove the clutch using a clutch puller remove the large center clutch
bolt (5/8 socket). You will need to use a small bar or large screwdriver and stick it through the clutch to stop the
clutch from rotating while you loosen the center bolt. Remove the center bolt, washers, and any spacers that are
there. Thread the clutch puller in by hand and tighten until the clutch pops off the shaft, you will need to hold the
clutch from rotating. Remove both clutches and the belt from the machine, go to step eight for complete secondary
clutch removal instructions. Place clutch on a clean work surface and remove clutch puller.
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