High Lifter Outlaw Clutch Kit for Arctic Cat 400i Auto 2x4_4x4 (03-08) - Manual (Page 2)

6. Remove the rest of the primary clutch off the machine. Remove the round metal plate using a #3 phillips
screwdriver. If you can’t get these screws loose, lightly tap the end of the screwdriver with a hammer while turning
the screwdriver. 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. Gasket part numbers are listed on the next page. Some
oil may leak from the housing when cover is first removed, this is normal.
7. Remove the nut (left handed threads usually a 24mm) holding the internal clutch on. Slide the clutch basket off,
keep track of which side faces out. Place the clutch on a clean work surface. Remove one end of each spring with 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 metal plates one at a time. This will allow you to see and change all of the primary
springs. Install the EPI springs by inserting the spring into the outer edge first. 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 down and reinstall spring. Slide the clutch
back onto the machine and install nut. Note: There is a directional bearing inside the clutch housing. If it
did not come out when removing the housing it should be good. If it came out, replace the bearing on the inner
sprague clutch. The arrow should be facing out so it points in the clockwise direction. Torque nut to 94 ft/lbs.
Clean both gasket surfaces, install new gasket and the aluminum housing. Torque the housing bolts to 7.2 ft/lbs.
Install the round metal plate.
8. Push the back half of the primary clutch onto the front shaft. Slide the center primary clutch shaft onto the front
shaft. Thread the bolt included in the kit into one of the holes near the center of the secondary clutch. This will
open up the clutch, place the belt into 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. With the belt inside the clutch, slide the secondary clutch onto the rear shaft, install nut and
torque to 75-85 ft/lbs.
9. 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 front shaft. This should
keep the rollers in place. Keep it pushed in until you can install the nut. The clutch should slide all the way back
easily, if the clutch doesn’t seem to go on far enough to tighten nut properly (it should slide all the way onto 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 further. Rolling clutch counter clockwise while pushing in will help the
clutch slide back on the splines. If rollers seem out of place take the clutch apart and check roller location. Install
nut and torque to 75-85 ft/lbs. Remove supplies bolt from secondary clutch.
10. Assemble the aluminum clutch cover and gasket. Attach the front and rear vent lines. Hook the brake cable into
the brake lever and install foot rest onto machine. Attach fenders to the foot rest and plug in the brake sensor
wires.
11. Install oil drain plug. Refill your engine oil to the proper level according to your 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.
12. 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.