High Lifter Outlaw Clutch Kit for Polaris 500 Sportsman HO (01-05) - Manual

8273 Industrial Park Road ▪ Baxter, MN 56425 ▪ (218) 829-6036 ▪ Fax (218) 829-1685
POLARIS OUTLAW SUPER DUTY KIT INSTRUCTIONS
Model : 500 SPORTSMAN HO 4x4 2001-2005 (27”-28” TIRES) Part # : HLCKP500HO
Kits designed for Stock motor and stock exhaust at 0-3000 feet elevation.
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
- 3/8, 7/16, 1/2 socket and wrench
- 5/8 socket
- Torque wrench
- Snap ring pliers
- Phillips screwdriver
- Side cutters
- 1/8 Allen wrench
- Primary Clutch Puller (EPI part # PCP-1)
1. Remove the key from the ignition. Remove the left side foot rest by unbolting it from the fenders and frame.
Remove the zip ties or clamps on the vent hose coming from the top of the clutch cover. On some models you
might have to remove the seat and the left side body panel between the front and rear fenders to gain access to the
vent tube. Be careful not to damage the rubber boot when cutting the zip ties.
2. Remove the clutch cover bolts, note the length of the bolts and their location. Some models might have a little
metal clamp at the rear of the cover that needs to be removed, simply take a flat tipped screw driver and pry the
clamp off. Save the clamp because you will need to reuse it. Remove cover slowly being careful not to damage the
gasket.
3. EPI found it easiest to remove both clutches and the belt at the same time but it is not required to install kit. If you
plan on removing both clutches remove the secondary (rear) clutch bolt (1/2” wrench or socket) and temporarily
leave clutch and belt on the machine. If you are NOT removing both clutches remove the belt. You can remove belt
by squeezing the belt together between the two clutches, this will allow enough slack in the belt to remove the belt.
The primary (front) clutch is pressed onto the crankshaft of the motor. Removal of the clutch is not required but
does make the job much easier. To remove the clutch a special clutch puller is needed, this tool is available through
EPI (part # PCP-1). Notice the “X” marked on the outside cover of the clutch, on the spider, and on the moveable
sheave. These are alignment marks from the factory and must line up when you reassemble the clutch. If you are
not removing the clutch see next step. To remove the clutch using a clutch puller, remove the large center clutch
bolt (5/8 socket). You need to use a small bar or large screwdriver and stick it through the clutch to stop the clutch
from rotating while you loosen the center bolt. Remove the center bolt, washers, and any spacers that are there.
Thread the clutch puller in by hand and tighten until the clutch pops off the shaft, you will need to hold the clutch
from rotating. Remove both clutches and the belt from the machine, go to step eight for complete secondary clutch
removal instructions. Place clutch on a clean work surface and remove clutch puller.
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 a 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.
EPIperformance.com