High Lifter Outlaw Clutch Kit for Polaris 500 Sportsman HO EFI (08-09 w_EBS) - Manual (Page 2)

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).
5. With the spring removed you can change the weights. Using an 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.
6. 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.
7. Install the RED colored primary spring. Make sure the spring fits flat into the clutch at both ends. Install the cover
plate making sure the “X” lines up. Tighten the six outside cover bolts evenly so the cover goes on straight to
prevent bushing damage. Install the center clutch bolt and torque to 45-47 ft/lbs. After riding your machine, if you
would like LOWER engagement than where this kit engages, you can install the MAROON colored spring. This
spring will LOWER your engagement 2-300 RPMs. If your kit only has one primary spring you can order this
optional spring through EPI.
8. Remove the secondary (rear) clutch by removing the center clutch bolt and pulling towards you. The clutch should
slide off the splined shaft. If the clutch sticks on the shaft spray some penetrating fluid on the shaft to help free it.
If it still doesn’t come off, you will need to order a secondary clutch puller available through EPI. When the clutch
does come off pay attention to the shims behind the clutch on the shaft. These shims effect the clutch alignment, if
they slide off the shaft be sure to put them back on.
9. Place the clutch face down so the four torx bolts / helix are facing up. Remove the four torx bolts. Pull up on the
helix. Note the position of the two rollers. Tighten compression tool in a vise (or can be drilled and mounted to
work bench). Thread one nut approximately 3/4 of the way down the threaded rod and then add washer. Slide clutch
over threaded rod putting the helix side facing up. Slide the collar, washer and the nut on. Tighten the top nut down
until there is slight pressure on the spring retainer allowing you to remove snap ring. Remove snap ring with snap ring
pliers. Slowly loosen the top nut on threaded rod allowing the spring to slowly expand. If you run out of threads before
all of the tension is off the spring lower the bottom nut to give you more space. Remove clutch from tool. Install the
EPI WHITE secondary spring. To install the spring, slide clutch on threaded rod. Place spring in clutch, place spring
retainer and snap ring on top of spring and add the washer and nut. Tighten nut until spring retainer is down far
enough to install snap ring. Install snap ring and remove clutch from tool. Install the EPI helix into clutch and push
down. Make sure that when you push the helix into the clutch you do not damage the two plastic rollers. Install the
four torx bolts. If needed, you can rotate the clutch in either direction to align the torx bolts. Push the helix down.
Tighten the four torx bolts to 42 to 52 inch pounds. Do not under or over tighten torx bolts.
10. If you removed both clutches from the machine it is easiest to install both clutches and the belt at the same time.
To install both clutches and the belt place the belt in the secondary clutch so the numbers on the belt read from left
to right. Squeeze the belt at the opposite end of the clutch to force the belt to open the secondary clutch and slide
the belt down into the clutch OR you can LIGHTLY tap on the belt with a plastic or rubber hammer to force the belt
into the clutch. Place the primary clutch through the belt and slide both clutches onto the machine. If you did not
pull the primary clutch off, you will need to place the belt in the primary clutch and install the secondary clutch onto
machine. Place the belt as much as you can into the secondary clutch, starting at the top of the secondary. If you
can’t get the belt completely on rotate the clutch so the belt rotates on. Torque the secondary clutch bolt to 15
ft/lbs. Torque the primary clutch bolt to 45-47 ft/lbs.
11. Install the plastic clutch cover making sure it seals properly. Install the small metal clip back onto the machine.
Tighten the clamps or zip ties to seal the vent tube on top of the clutch cover. Install the side panel and seat.
Install the foot rest and prepare to ride.
12. If after riding the machine something doesn’t seem right, double check that the secondary clutch has been
assembled correctly.
NOTICE: Even with this clutch kit, you should be advised that using substantial throttle when the tires are not able to
spin can cause the belt to slip and damage may occur. EPI recommends that the transmission be shifted into low
range when high load, slower speed situations are encountered. EPI is not responsible for any damage to the drive
belt or any other original equipment component.