User Manual

8273 Industrial Park Road ▪ Baxter, MN 56425 ▪ [phone] ▪ Fax [phone]
POLARIS OUTLAW SUPER DUTY CLUTCH KIT INSTRUCTIONS
Model: 800 SPORTSMAN EFI HO 4x4 2008 (29.5” TIRES) Part #: HLCKP800FI-1-SX
800 SPORTSMAN EFI 4x4 2009 (29.5” TIRES)
Kits designed for Stock motor and stock exhaust a t 0-3000 feet elevation.
ATV ’ s can be da ngerous. EPI has n o control ov e r the use of any pa r t. EPI expects the cu s tom e r to exercise good
judgment as to the prop er selection, in s tallation, use and m ainten a nce of an y part. E PI assum es no res ponsibili ty for
damage or injur y of any kind because of misus e, improper installa tion and improper application of any parts in any w ay
by an y pe r s on. Con ta c t your loc al dealer to sch ed ule installation of this clutc h kit if you ar e not a qualified ATV
mechanic.
This pr oduct is NOT to be instal led on any AT V t ha t will be used by any pe rson unde r t he age of 16.
TOOLS NEEDED TO INSTALL CLUTCH KIT
- 3/8, 7/16, 1/ 2 s oc ket and wrenc h
- 5/8 socket
- Torque wrench
- Snap ring pliers
- Phillips screw dr iver
- Side cutters
- 1/8 Allen w r ench
- # 25 Torx wrench
- Prima r y Clutch Puller (EPI par t # P CP-1)
- Clu tc h Compres s ion Tool ( EPI par t #CCT510 )
ENGAGEMENT
- 17-1,800 RP M s
1. Remove the key fr om the ignition. Rem ove the left side foot res t b y unb olting it f r om the fe nders a nd frame.
Remove the zip ties or c lamps on the v e nt hose coming from the top of the clutc h cover. On som e models you
might h ave to rem ove the s ea t and th e le ft side body pan el betw een the fron t a nd rear fenders to gain a c cess to th e
vent tube. Be carefu l not to damage the ru bber boot when cutting th e z ip ties.
2. Rem ove the clutch cover bolts ; note the length of the bolts and their location. Som e m od els migh t have a little
metal clamp at the rear of the cover tha t needs to be removed, simply take a flat tipp ed s c r ew driver an d pr y the
clamp off . Save the clamp bec a use you will need to reuse it. Remove cover s lowly being c a r eful not to damage the
gasket.
3. EPI found it ea siest to r e m ove both clutc hes and the belt at th e s ame tim e but it is not requ ir ed to install kit. If you
plan on removing both c lutche s r e m ove the se c ondary (rear ) clutch bolt ( 1/2” w r ench or socket) a nd temporarily
leave c lutch a nd belt on the machine. If you a re NOT remov ing both clutches remove the belt. You can remove belt
by squeezin g the belt tog ether between the two clutches, this will a llow enou g h slack in the belt to r em ove the belt.
The pr im ary (front) clutch is pres sed ont o the cra nksha ft of th e m otor . Removal of th e c lutch is not required bu t
does make the job m uch e a s ie r . To remove the c lutch a special c lutch puller is needed, this tool is a vailable through
EPI (part # PCP-1). Notice the “X” mark e d on the outside c over of the clutc h, on the spider, a nd on the moveable
sheave. These are alignment marks from the factory and must line up when you reassemble the clutch. If you are
not removing th e c lutch see nex t step. To r e m ove the clutch using a clutch puller remove the lar ge center clutch
bolt (5/8 socket). You will need to use a sm all bar or la r g e screw dr iver and stick it through the clutch to stop the
clutch from r otating while you loosen the cente r bolt. Re m ove the c enter bolt, washers , and any s p a c e r s that are
there. T hread the clutc h puller in by hand a nd tighten until th e clutch pops off the shaft, you will nee d to hold the
clutch from r otating. Remove both clutches a nd the belt fr om the mac hine, go to step eight for c om plete seconda ry
clutch remov al instr uctions . Place clutch on a clean work surface and remove clutch puller.
ERLANDSON PERFORMANCE, INC.
EPIperformance.com