8273 Industrial Park Road ▪ Baxter, MN 56425 ▪ (218) 829-6036 ▪ Fax (218) 829-1685
SUZUKI OUTLAW SUPER DUTY KIT INSTRUCTIONS
Model: 500 KING QUAD AXi 4x4 2009 (28”-29.5” TIRES) Part #: HLCKS500KQ-SX
Kits designed for Stock motor and stock exhaust at 0-3000 feet elevation.
ATV’s can be dangerous. EPI has no control over the use of any part. EPI expects the customer to exercise good
judgment as to the proper selection, installation, use and maintenance of any part. EPI assumes no responsibility for
damage or injury of any kind because of misuse, improper installation and improper application of any parts in any way
by any person. Contact your local dealer to schedule installation of this clutch kit if you are not a qualified ATV
mechanic.
This product is NOT to be installed on any ATV that will be used by any person under the age of 16.
Tools needed to install clutch kit
- Metric socket set
- Torque wrench
- Spring tool or needle nose pliers
- 1/2” impact wrench
- Suzuki oil
- Punch or spanner wrench
- Phillips and flat tip screwdrivers
- Clutch Compression Tool (EPI part # CCT510)
- Clutch shoe remover (Suzuki part # 09920-33540)
- Sliding shaft (Suzuki part # 09930-30104)
Gaskets needed
- Order gaskets from you local dealer before you install clutch kit
- Internal clutch housing gasket - part # 11482-11-H00
Engagement
2,000 RPMs
1. Remove the key from ignition. Remove the right side foot rest including the metal support bracket. Remove the
clutch cover. Note the length of the bolts and their location.
2. Once the clutch cover is removed you should be able to see both clutches. Remove the aluminum clutch guard.
Remove the bolt that holds the primary clutch (front clutch) on. Pull the clutch off the machine and place on a flat
clean surface. Slide the inside plate up and out of the clutch. This should reveal eight clutch rollers.
3. Remove one of the stock rollers and press the center weight out of the roller housing. Press in the new weights,
supplied in the kit into the roller housings and place the roller back in the clutch. The weights can only be pushed
into the housings one direction, make sure you are pushing it out the right way or damage can occur. Repeat this
step for the remaining rollers. NOTE: If your kit has two different weights, be sure to place them directly
across from each other (or every other one). This keeps the clutch in balance. Make sure you have all eight
of the rollers in the proper place and position. Install the inside plate making sure all the rollers are in the proper
location. Place clutch out of the way and start working on the secondary clutch.
4. Remove the bolt that holds the secondary clutch on. Remove the clutch and belt from the machine. Using a
spanner wrench or punch and a hammer loosen the large nut holding the secondary spring retainer. ONLY TURN
NUT 1/2 TURN, DO NOT TOTALLY REMOVE NUT. The nut and retainer are under extreme pressure and
can cause damage or injury if not removed properly. Using the compression tool (EPI part #CCT510) carefully
compress the spring enough to take the pressure off the nut. Remove the nut and slowly release the pressure off
the spring. Remove the spring.
(6 pages)
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