High Lifter Outlaw Super Duty Extreme Clutch Kit for Arctic Cat 1000 Thunder Cat H2 (08-10) - Manual (Page 2)

6. Install the EPI secondary spring in the #1 hole in the helix and the B setting in the clutch. Align the helix on the
splined shaft and place the snap ring on the helix. Using the compression tool (EPI part # CCT510) slowly and
carefully compress about halfway down. While holding the helix and the bottom half of the clutch from moving, turn
the top half of the clutch counterclockwise approximately a 1/3 of a turn so the plastic buttons in the clutch rotate
past the next ramp on the helix. Push the helix down and install the key way and the snap ring. Once the snap ring
has been installed you can remove the clutch from the press. Set the clutch aside.
7. Remove the oil drain plug from the motor; if you can carefully drain it into a clean container you should be able to
reuse it. After oil is drained, remove the primary clutch inner sheave and center spacer, then remove the bolts that
hold the aluminum housing that contains the internal clutch. This is the housing that has the shaft sticking out of it
that the primary clutch sits on. Slowly remove the housing, try not to damage the gasket. If gasket is damaged
you will need to install a new one. Some oil may leak from the housing when first removed, this is normal. Note:
There is a directional bearing inside the clutch housing that could fall out while removing the housing. Be
sure to locate this directional bearing and either set it aside for reassembly or place it back in the housing you just
removed.
8. Remove the nut (left handed threads) holding the internal clutch on. Slide the clutch basket off; keep track of which
side faces out. Place clutch on a clean work area. 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 change the inner sprague springs. Remove the stock sprague 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 hole.
Install the three metal plates and the e-clips. Slide the clutch basket back onto the machine. Install the nut and
torque it to 94 ft/lbs. If the directional bearing came out, replace the bearing on the inner Sprague clutch. The
bearing is stamped indicating which side faces out. Make sure to put the bearing on making sure the stamping is
facing out, if it did not come out when removing the housing it should be good. Install the gasket and install the
aluminum housing. Torque the housing bolts to 7.2 ft/lbs.
9. Replace the inner half of the primary clutch and center spacer back onto the shaft. Put the secondary clutch on;
make sure it slides on all the way. Torque the nut to 72 ft/lbs. Thread the bolt included in this kit into one of the
threaded holes on the side of the secondary clutch. This should spread the clutch sheaves apart. Put the belt in 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.
10. 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 shaft. This should keep the
rollers in place. Keep it pushed in until you can install the nut and washer. The clutch should slide all the way back
easily. If the clutch doesn’t seem to go on far enough to tighten the nut properly (it should slide all the way on so
that the splines on the shaft are showing approximately 1/16 of an inch) 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 farther. If the
rollers seem out of place take the clutch apart and check roller location. Install the large nut and torque it to 83
ft/lbs. Remove the bolt that was threaded into the secondary clutch.
11. Carefully install the clutch cover and gasket to ensure a good seal. Install the foot rest including the brake pedal
and metal support bracket if they were removed. Attach the fenders to the foot rest.
12. Install oil drain plug. Refill your engine oil to the proper level according to owners manual. You can reuse your oil
if it is clean and was drained into a clean container. You must use NON Friction Modified oil (stock Arctic Cat). DO
NOT use oils with Friction Reducing Agents, this WILL CAUSE SLIPPAGE AND DAMAGE.
13. 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.