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

8. Using an impact wrench and 27mm socket remove the nut and washer in the center of the clutch. Using the Honda
tool # 07933-HB3000A, thread the large part of the tool into the center of the clutch. Tighten the center bolt on the
tool while holding the large part of the tool with a wrench. This will pull the clutch and outer housing off the
machine. There is a directional bearing in the clutch housing, if bearing is removed or falls out make sure arrow on
the bearing is pointing in the clockwise direction as you face the bearing when placed in the housing. This bearing
does not need to be removed. Slide clutch out of housing and place on a clean work surface.
9. Remove one end of each spring using a spring tool or pliers. Push down slightly on the outside cover and remove
the 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 (45 or 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 clutch into the housing and then slide housing onto machine. Install washer and new lock nut
#90235-HM7-00 and torque to 87 ft/lbs. After torquing, don’t forget to restake the lock nut.
10. Clean the gasket off the cover and the crankcase. Install new gasket and the crankcase cover. Slide crankcase
cover on slowly making sure all internal parts line up properly. Make sure you put the proper length bolt in each
hole. Torque bolts to 9ft/lbs.
11. Install the oil lines; make sure the o-rings are in place. If oil leaks where the lines go into the motor you are
missing an o-ring or have a damaged o-ring. Install the both left and right side inner fenders, right side lower
fender, and the plastic motor guards onto the machine.
12. Install oil drain plug. 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 levels after the machine has run for a few minutes.
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.