High Lifter Outlaw Super Duty Extreme Clutch Kit for Polaris 800 Sportsman EFI HO 4x4 w_EBS (10-13) - Manual (Page 2)

5. Install the WHITE colored primary spring. Make sure the spring fits flat into the clutch at both ends. Install the
cover plate making sure the “X” lines up. Tighten the six outside cover bolts evenly so the cover goes on straight to
prevent bushing damage. Install the center clutch bolt and torque to 45-47 ft/lbs. After riding your machine, if you
would like LOWER engagement than where this kit engages, you can install the SILVER colored spring. This spring
will LOWER your engagement 2-300 RPMs. If your kit only has one primary spring you can order this optional
spring through EPI.
6. Remove the secondary clutch by removing the center clutch bolt and pulling towards you. The clutch should slide off
the splined shaft. If the clutch sticks on the shaft spray some penetrating fluid on the shaft to help free it. If it still
doesn’t come off, you will need to order a secondary clutch puller (EPI part #SCP-1). When the clutch does come off
pay attention to the shims behind the clutch on the shaft. These shims effect the clutch alignment, if they slide off
the shaft be sure to put them back on.
7. Place the clutch face down so the spring and spring retainer are facing up. Using a compression tool (EPI part #
CCT510) carefully compress the spring enough to take the pressure off the snap ring. Remove the snap ring, spring
retainer and spring. Place the EPI PURPLE secondary spring and spring retainer in the clutch. Using the
compression tool, slowly and carefully compress the spring until you can install the snap ring.
8. Install the belt in the secondary clutch so the numbers on the belt read from left to right. Install clutch onto the
shaft and tighten bolt to 15 ft/lbs. Grab the primary clutch, place the belt into the clutch and install the clutch onto
the shaft. Torque the primary clutch bolt to 45-47 ft/lbs. If you haven’t pulled the primary clutch off or if you need
the belt looser to install the clutch you need to get the clutch sheaves to open so the belt can drop down into the
clutch. This will give you enough slack in the belt to feed it around the primary clutch and then slide the secondary
clutch onto its shaft and reinstall the bolt that holds it in place. With the machine in neutral, spin the clutches by
hand until the secondary has shifted back to its closed position and the belt is riding at the top of the sheaves. If you
fail to do this it will be like starting out in high gear when you try to drive it for the first time and you will possibly
burn the belt. Torque the secondary clutch bolt to 15 ft/lbs.
9. Install the plastic clutch cover, making sure it seals properly. Tighten the clamps to seal the vent tube on top of the
clutch cover. Install the foot rest, plastic fender dart, side panel, and the seat.
10. Go out and ride your machine. If after riding the machine something doesn’t seem right, double check to make
sure everything has been assembled correctly.
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.