High Lifter Outlaw Clutch Kit for Honda 500 Foreman 2x4_4x4 (05-11) - Manual

8273 Industrial Park Road ▪ Baxter, MN 56425 ▪ (218) 829-6036 ▪ Fax (218) 829-1685
HONDA OUTLAW SUPER DUTY KIT INSTRUCTIONS
Model: 500 FOREMAN 4x4 2005-2009
Part #:HLCKH500FM-P
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
- Set of metric sockets
- 27mm socket
- Phillips and flat tip screwdrivers
- Torque wrench
- Spring tool or needle nose pliers (45 or 90 degree bent pliers work well)
- 1/2” impact wrench
- Honda motor oil
- Honda clutch tool # 07933-HB3000A
- 5mm Allen wrench
NEEDED TO INSTALL CLUTCH KIT
- Order from your local dealer before you install clutch kit.
- Crankcase cover gasket # 11394-HPO-A00
- Lock Nut # 90235-HM7-00
1. Remove the key from the ignition switch. Raise front end and remove front tires. Remove the left and right side
inner fenders.
2. Remove the oil drain plug from the motor; if you can carefully drain it into a clean container you should be able to
reuse it. Loosen and remove the oil lines on the front of motor (5mm Allen wrench). Note line Location for proper
assembly.
3. Remove both foot well braces. Remove the right side lower fender.
4. Remove the right and left side engine panels and covers.
5. Remove cooling fan assembly. Unplug electrical connector. Leave vent tube hooked up. Tie the vent tube out of
the way.
6. Remove oil lines from front of engine (10mm socket). Remove the 4 bolts that attach oil cooler to the frame. Tie oil
cooler out of the way.
7. Remove the front crankcase cover bolts; keep track of each bolt length and location. Do not loosen or remove
tension adjuster nut on crankcase cover. Slide crankcase cover off slowly. Watch for internal parts inside the cover
on the left side of the machine so you know how they go back on. Watch for 2 washers lying inside the cover when
removed. They will normally stick to the cover or will remain sitting on the small shaft with the shift lever.
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