High Lifter Outlaw Clutch Kit for Honda 350 Rancher Springs Only (00-05) - Manual (Page 2)

7. Remove one end of each spring using 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 round metal plates one at a time. This will
allow you to see and remove the complete spring. Install the EPI springs by inserting the spring into the outer edge
first. Using a spring tool or pliers (45 degree bent pliers work well) pull on the spring and insert the end into the
hole. Install the three metal plates and the e-clips. If you can’t get the plates to sit flat make sure each clutch arm
is flat against the bottom plate of the clutch. Occasionally when you put the springs on, the clutch arms will pop up.
Slide the clutch into the housing and then slide housing onto machine. Install washer and nut and torque to
87 ft/lbs.
8. Take the shift fork and the triangle shaped bearing from the cover and place onto the motor so the shift fork
straddles the lower shift linkage. Place the shift fork on first, then the spring, and then add the triangle shaped
bearing. Clean the gasket off the cover and the crankcase. Wipe off any excess oil inside the cover. Put a thin
layer of Yamabond semi-drying liquid gasket (or something similar as long as it is semi-drying) on the crankcase
cover. Carefully install crankcase cover, do not force cover on. You will have to align the small shaft through the
cover and you may need to turn the large shaft to properly align the splines on the shaft. If the cover is most of the
way on and stops you may need to wiggle the small shaft slightly to allow the cover to go on completely. Torque
cover bolts to 9 ft/lbs.
9. Grab onto to the end of the front driveshaft and push towards the front of the machine until you can slide the
driveshaft onto the shaft from the motor. Slide the front differential into place and install mounting bolts, do not
tighten until all the bolts have been installed. Some models may use a spacer on the top bolt, be sure that spacer is
installed. Install the front skid plate. Make sure both rubber boots on the shaft are in the correct location and the
rubber o-rings are on both ends to hold them in place.
10. Install the shift solenoid on the front of the cover. Install the oil lines onto the motor. Plug the wires into the front
of the cover and install the left side motor cover. Install the inner front fender wells, the lower front fenders, and
the foot rest on both sides.
11. Install the oil drain plug. Refill your engine to the proper level according to your owner’s manual. You can reuse
your oil if it is clean and was drained into a clean container. Only use manufactures recommended oil. Be sure to
double check oil levels and to look for any oil leaks after the machine has run for a few minutes.
12. Go out and ride your machine. If your performance doesn’t seem right double check to make sure everything has
been done properly.