High Lifter Outlaw Super Duty Extreme Clutch Kit for Polaris 800 Ranger 6x6, XP, HD, Crew (10-12) - Manual

8273 Industrial Park Road ▪ Baxter, MN 56425 ▪ (218) 829-6036 ▪ Fax (218) 829-1685
POLARIS SUPER DUTY EXTREME KIT INSTRUCTIONS
Model : 800 RANGER CREW/HD/XP 4x4 2010 (28”-29.5” TIRES) Part # : HLCKP800R-SX
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
- 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 seat bottom cushion. Remove the plastic storage compartment
from under the driver side seat by removing the bolts around the storage compartment door and sliding the
compartment out of the frame. This will expose the clutch cover for easy access.
2. Using a screwdriver, loosen the clamp that holds the vent hose on the top of the clutch cover. 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 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.
4. If you are not pulling the primary clutch off the machine OR if you already have the clutch off the machine, remove
the six outside bolts from the cover. Next remove the center bolt allowing the cover and spring to be removed (this
bolt is already removed if clutch is off the machine).
EPIperformance.com