High Lifter Outlaw Clutch Kit for Honda 500 Rubicon Springs Only - Manual (Page 2)

7. Using a 27mm socket remove the retainer nut and washer from the center of the Sprague clutch. You might need
to use a standard or thin wall socket, not all impact sockets will fit into the clutch. Thread the large part of Honda
clutch puller number #07ZMC-HN2A100 into the clutch and tighten the smaller part of the tool. While holding the
large part of the tool from spinning tighten the small part of the tool until the clutch slides off of the machine. When
you pull the clutch off of the machine watch for a washer that sits behind the clutch. If this washer comes off just
slide it back onto the shaft. Remove the inner clutch from the outer housing and place on a clean work surface.
8. Remove one end of each spring using a spring tool or a needle nose pliers. Push down slightly on the outside cover
and remove the six e-clips. Keeping track of which way they come off remove the three round metal plates one at a
time. This will allow you to see and remove the complete spring. Install the EPI springs by inserting the spring into
the outer edge first. Using a spring tool or pliers (90 degree bent pliers work well) pull on the spring and insert the
end into the hole. Install the three metal plates and the e-clips. If you can’t get the plates to sit flat make sure
each clutch arm is flat against the bottom plate of the clutch. Occasionally when you put the springs on the clutch
arms will pop up. Slide the outside clutch housing onto the shaft, make sure the gear on the back of the housing fits
together properly with the other gear on the machine. You can rotate the housing until it fits properly. Once the
housing is on the shaft all the way slide the rest of the clutch into the housing. Install the washer and nut and
torque to 87 ft/lbs.
9. Clean the gasket material off the crankcase and the crankcase cover. Wipe off any excess oil inside of the cover.
Put a thin layer of Yamabond semi-drying liquid gasket (or something similar as long as it is semi-drying) on the
crankcase cover. Carefully install crankcase cover, do not force the cover on. If cover doesn’t slide on easy check
to see if it is catching on the rubber pad on the skid plate and that the shaft is aligned properly with the case.
Torque cover bolts to 9 ft/lbs.
10. Install the solenoid back onto the motor and plug in the wire harness. Install the shifter linkage onto the shaft,
make sure your alignment marks line up with each other. Put the other end of the shifter linkage together by
placing the in through the hole, then add the washer and install the cotter pin. Take a flat tip screwdriver and lift up
spring to allow it to snap into place on both the top and the bottom. Install the upper side body panel by the shifter
knob. Install the metal bracket and the plastic side cover on the left side of the machine.
11. Bolt the oil tank onto the machine, make sure the o-rings are clean and in good condition. Connect the oil lines to
the oil tank. Connect the oil sensor wire at the bottom of the oil tank. Install both oil drain plugs. Refill your engine
oil to the proper level according to your owners manual. You can reuse your oil if it is clean and was drained into a
clean container. Only use manufactures recommended oil. Be sure to double check oil level after the machine has
ran for a few minutes.
12. Install the left and right side inner fender wells and the metal brackets holding them on. Install the left and right
side front fenders. This should complete installation, if you have any extra parts do not use your machine until you
figure out where they need to go.
13. Go out and ride your machine. Check for any oil leaks. If your performance doesn’t seem right double check to
make sure everything has been done properly.