High Lifter Outlaw Super Duty Extreme Clutch Kit for Arctic Cat 700 EFI (06-08) - Manual (Page 2)

4. Remove the bolt that holds the secondary clutch on. Remove the clutch and belt from the machine. Using a
spanner wrench or punch and a hammer loosen the large nut holding the secondary spring retainer. ONLY TURN
NUT 1/2 TURN - DO NOT TOTALLY REMOVE THE NUT. The nut and retainer are under extreme pressure and can
cause damage or injury if not removed properly. Using a compression tool (EPI part #CCT510) carefully compress
the spring enough to take the pressure off the nut. Remove the nut and slowly release the pressure off the spring.
Rotate the spring retainer counter clockwise to the next hole.
5. Place the spring retainer on top of the spring. Set the nut on top of spring retainer, using the compression tool or
press slowly and carefully compress the spring until the retainer is at the top of the shaft. Rotate the spring retainer
so the flat spots line up properly to fully compress the spring. Once the retainer is in place tighten the nut, remove
the clutch from the press and torque the nut to 72.5 ft/lbs.
6. Remove the oil drain plug from the motor. If you can, carefully drain the oil into a clean container. You should be
able to reuse the oil.
7. Remove the rest of the primary clutch off of the machine. Loosen and remove the front and rear vent lines off of
the plastic housing cover. Remove the bolts holding the plastic housing cover and remove cover. Remove the bolts
holding the aluminum clutch housing; keep track of each bolt length and location. Once all the bolts have been
removed slowly pull the cover towards you being careful not to damage the gasket. If the gasket is damaged you
will need to install a new one. Some oil may leak from the housing when first removed, this is normal. Note:
There is a directional bearing inside the clutch housing that could fall while removing the housing.
8. Remove the nut (left handed threads usually a 24mm) holding the internal clutch on. Using the Suzuki clutch shoe
remover and sliding shaft, remove the clutch basket from the shaft, keep track of which side faces out. Place the
clutch on a clean work surface. Push down slightly on the outside cover and remove the e-clips. Keeping track of
which way they come off remove the three metal plates one at a time. This will allow you to see and change the
complete primary spring. Install the EPI springs by inserting the spring into the outer edge first. You may need to
use a punch and hammer to get the spring hook into the hole. Using a spring tool or pliers pull on the spring and
insert the end into the inner hole. Install the three inner plates and the e-clips. If the three plates don’t seem to fit
flat or correctly to install the e-clips, check to see if one of the five Spragues is sticking up. If it is remove one end
of the spring on the Sprague that is sticking up, push it down and reinstall spring. Slide the clutch back onto the
machine and install nut. Torque to 94 ft/lbs. If the directional bearing came out, replace the bearing on the inner
Sprague clutch. Put the bearing on making sure the arrow is facing towards the rear of the machine, if it did not
come out when removing the housing it should be good. Install the gasket and install the aluminum housing.
Torque the housing bolts to 7.2 ft/lbs.
9. Bolt on the clutch housing and any other brackets that were removed. Push the back half of the primary clutch back
onto the shaft. Put the secondary clutch on; make sure it slides on all the way. Torque the nut to 83 ft/lbs. Thread
the bolt included in this kit into one of the threaded holes on the side of the secondary clutch. This should spread
the clutch sheaves apart. Put the belt in the clutch. Most belts have an arrow indicating direction of rotation. If
your belt doesn’t, be sure to install it so that you can read the part number. In either case, always run the belt the
same direction as it was new.
10. Grab the primary clutch, push the inner part down with your thumbs and hold down as you pick up the clutch.
While holding the inner part of the clutch from moving, slide the primary clutch onto the shaft. This should keep the
rollers in place. Keep it pushed in until you can install the bolt and spacer. The clutch should slide all the way back
easily. If the clutch doesn’t seem to go on far enough to tighten the bolt properly (it should slide all the way on to
the edge of the splines) you might have a roller out of place or the belt might be blocking it. If needed, move the
belt up and down to see if the clutch will slide on farther. If the rollers seem out of place take the clutch apart and
check roller location. Install the bolt and torque it to 85 ft/lbs. Remove the bolt that was threaded into the
secondary clutch.
11. Assemble the clutch cover and gasket. Install the metal foot rest bracket and plastic foot rest.
12. Install oil drain plug. Refill your engine oil to the proper lever according to owners manual. You can reuse your oil
if it was clean and was drained into a clean container. Only use manufactures recommended oil for proper engine
and clutch operation.
13. Go out and ride your machine. If the performance doesn’t seem right double check to make sure everything has
been done properly.
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.