High Lifter Outlaw Super Duty Extreme Clutch Kit for Polaris 800 RZR "S, RZR "4" (10-13)" - Manual

8273 Industrial Park Road ▪ Baxter, MN 56425 ▪ (218) 829-6036 ▪ Fax (218) 829-1685
POLARIS SUPER DUTY EXTREME KIT INSTRUCTIONS
Model : 800 RZR S 2010 / 800 RZR 4 2010 (28”-29.5” TIRES) Part # : HLCKPRZRS-1-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 and wrench
- #25 Torx
- Torque wrench
- Phillips and flat tip screwdrivers
- 1/8 Allen wrench
- Clutch Compression Tool (EPI part #CCT510)
- Primary Clutch Puller (EPI part #PCP-12)
ENGAGEMENT
21-2,200 RPMs
1. Remove the key from the ignition. On RZR S models remove the driver and passenger seats. Remove the two torx
screws from the rear of the center console. On RZR 4 models remove both rear seats. Remove the plastic rear
service panel to access the engine compartment. Remove the two bolts holding the seat cross bar and remove the
cross bar. Remove one of the clamps on the vent hose coming from the top of the clutch cover. Be careful not to
damage the rubber boot. Save the clamp because you will need to reuse it. Remove the eight clutch cover bolts.
Note the location of the bolts. Remove the clutch cover and set aside.
2. Remove the belt. You can remove belt by pulling up on the belt to open the driven clutch, this will allow enough
slack in the belt to remove it.
3. Next remove the primary clutch (clutch on passenger side). Remove the center bolt (5/8 socket), washers, and any
spacers that are there. 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. Thread the clutch puller (EPI part #PCP-12) in by hand
and tighten until the clutch pops off the shaft. You will need to hold the clutch from rotating. Remove the primary
clutch and place on a flat clean work surface and remove the clutch puller. Notice the part numbers and/or “X” on
the outside cover of the clutch and the “X” marked on the spider. These are alignment marks from the factory and
must line up when you reassemble the clutch. While pushing down on the clutch cover remove the six outside bolts
from the primary clutch cover. Caution – the clutch and clutch cover are under spring tension and can
cause damage or injury if not removed properly. Remove the cover and spring.
4. With the spring removed you can change the weights. Using a 1/8” Allen wrench and a 3/8” wrench or socket
remove the bolt holding the weight in the clutch. Replace the stock weight with the weight included in the clutch kit
and install the bolt and nut. Repeat the same process for the other two 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. Clean clutch bushings by wiping them with a clean dry rag. This applies to both
clutches.
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