High Lifter Outlaw Super Duty Extreme Clutch Kit for Polaris 550 Sportsman XP EFI 4x4 (09-10) - Manual

8273 Industrial Park Road ▪ Baxter, MN 56425 ▪ (218) 829-6036 ▪ Fax (218) 829-1685
POLARIS SUPER DUTY EXTREME KIT INSTRUCTIONS
Model
: 550 SPORTSMAN XP EFI 4x4 2009-2010 (27”-28” TIRES) Part # : HLCKP550_
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, 5/8, ½, 15mm, 17mm, 18mm socket and wrench
- Torque wrench
- Snap ring pliers
- Phillips screwdriver
- 1/8 Allen wrench
- #25 & 40 Torx wrench
- Primary Clutch Puller (EPI part # PCP-12)
- Clutch Compression Tool (EPI part #CCT510)
ENGAGEMENT
- 2,800 RPMs
1. Remove the key from the ignition. Using the #40 Torx, remove the rear plastic skid plate. Jack up the rear of the
machine and remove the left rear wheel. Make sure the machine is stable – we suggest supporting the left wheel
hub on a block or jack stand. Use a 15mm socket to remove the 4 bolts that secure the removable section of
frame alongside the clutch cover.
2. Remove the clutch cover bolts. The top 2 bolts can be accessed easier from the top by removing the seat. Remove
the cover by sliding it out towards you through the opening in the frame. It’s a tight fit but it will come out with
enough patience!
3. Next grab the belt on the side closest to you and pull on it to slightly open the secondary clutch sheaves. This will
give you just enough slack to make removing the primary clutch easier. Remove the primary clutch retaining bolt.
NOTE: THIS BOLT HAS LEFT-HAND THREADS SO TURN IT CLOCKWISE TO LOOSEN. Be sure to remove all
washers and the black plastic spacer from inside the clutch when removing this bolt. Using the EPI Clutch Puller
PCP-12, remove the primary clutch from the motor. Thread the clutch puller in by hand and tighten with a wrench
until the clutch pops off the shaft, you will need to hold the clutch from rotating while doing this. Remove the clutch
and place it on a clean surface.
4. Notice the printing on the outside cover of the primary clutch and the “X” stamped on the spider, and on the
moveable sheave. These are alignment marks from the factory and must line up when you reassemble the clutch.
Remove the six outside bolts from the cover, set the cover and stock spring aside. Using a 1/8” allen wrench and a
3/8” wrench or socket remove the nut from the pin holding the weight in the clutch and slide the pin out of the
weight. Replace the stock weight with a weight included in the clutch kit and install the bolt and nut. Repeat the
same process for all weights.
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.
EPIperformance.com