High Lifter Outlaw Super Duty Extreme Clutch Kit for Polaris 700 Ranger Crew (08-09) - Manual (Page 2)

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. 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. 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 pin holding the weight in the clutch. Replace the stock weight with the weight included in the clutch kit
and install the pin and nut. Repeat the same process for the other two weights.
6. It’s a good idea to clean your clutches. Using a clean rag and a contact/brake cleaner that DOES NOT leave an oily
film or residue, clean all areas of the clutch except on the bushings. Cleaning the clutch bushings with a cleaning
solvent can cause premature wear. This applies to both clutches.
7. Install the RED colored primary spring. Make sure the spring fits flat into the clutch at both ends. Install cover
onto clutch being sure to align the “X” marks as noted when you disassembled it. Make sure the cover lines up
properly on the clutch towers so the two raised areas on the cover seat properly. Damage can result if this is not
done properly. Tighten the six outside cover bolts evenly so the cover aligns and seats properly into the clutch
towers to prevent damage. Install the center retaining bolt and torque to 45-47 ft/lbs. After riding your machine, if
you would like HIGHER engagement than where this kit engages you can install the ORANGE colored spring. This
spring will RAISE your engagement 3-400 rpms.
8. Remove the secondary (rear) 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.
9. CAUTION: The spring retainer will have spring tension on it and can pop up and out of the clutch when
snap ring is removed. Using a compression tool or a press, carefully compress the spring enough to take the
pressure off the spring retainer. Remove the snap ring, spring retainer and spring.
10. Place the EPI PURPLE secondary spring and spring retainer in the clutch. Using the compression tool or a press,
slowly and carefully compress the spring until you can install the snap ring.
11. If you removed both clutches from the machine it is easiest to install both clutches and the belt at the same time.
To install both clutches and the belt; place the belt in the secondary clutch so the numbers on the belt read from
left to right. Squeeze the belt at the opposite end of the clutch to force the belt to open the secondary clutch and
slide the belt down into the clutch OR you can LIGHTLY tap on the belt with a plastic or rubber hammer to force the
belt into the clutch. Place the primary clutch through the belt and slide both clutches onto the machine. If you did
not pull the primary clutch off, you will need to place the belt in the primary clutch and install the secondary clutch
onto machine. Place the belt as much as you can into the secondary clutch, starting at the top of the secondary. If
you can’t get the belt completely on rotate the clutch so the belt rotates on. Torque secondary clutch bolt to 15
ft/lbs.
12. Install the plastic clutch cover making sure it seals properly. Install the small metal clamp back onto the rear of the
clutch cover. Tighten the clamps or zip ties to seal the vent tube on top of the clutch cover. Install the plastic
storage compartment under the driver side seat. Install the seat bottom cushion and prepare to ride.
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.