High Lifter Outlaw Clutch Kit for Polaris 800 Sportsman EFI HO 4x4 w_EBS (10-13) - Manual

8273 Industrial Park Road ▪ Baxter, MN 56425 ▪ (218) 829-6036 ▪ Fax (218) 829-1685
POLARIS OUTLAW SUPER DUTY CLUTCH KIT INSTRUCTIONS
Model : 800 SPORTSMAN EFI 4x4 2010 (27”-28” TIRES) Part # : HLCKP800FI-2
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
- #20 and #27 Torx
- Torque wrench
- Phillips and flat tip screwdrivers
- 1/8 Allen wrench
- Clutch Compression Tool (EPI part #CCT510)
- Primary Clutch Puller (EPI part #PCP-1)
ENGAGEMENT
21-2,300 RPMs
1. Remove the key from the ignition. Remove the seat, left side foot rest and the plastic dart the holds the rear fender
onto the frame under the seat. Remove the left side panel and loosen 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. Next remove the primary clutch. 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-1) 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.
3. 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.
4. 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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