High-lifter Outlaw Super Duty Extreme Clutch Kit for Suzuki Ki User Manual download pdf (Page 2)

5. Place the EPI spring in the clutch. Place the spring retainer on top of the spring. Set the nut on top of spring

retainer, using the compression tool (EPI part #CCT510) carefully compress the spring until the retainer is at the top

of the shaft. Rotate the spring retainer so the flat spots line up properly to fully compress the spring. Once the

retainer is in place tighten the nut, remove the clutch from the press and torque the nut to 72.5 ft/lbs.

6. Remove the oil drain plug from the motor. If you can, carefully drain the oil into a clean container. You should be

able to reuse the oil.

7. Remove the rest of the primary clutch off of the machine. Loosen and remove the front and rear vent lines off of

the plastic housing cover. Remove the bolts holding the aluminum clutch housing; keep track of each bolt length

and location. Once all the bolts have been removed slowly pull the cover towards you being careful not to damage

the gasket. If the 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

while removing the housing.

8. Remove the nut (left handed threads usually a 24mm) 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 (c-clamp or large pliers work well). Keeping track of which way they come off remove the round

metal plates. This will allow you to see and change the complete spring. Using a spring tool or needle nose pliers

remove the stock springs. You might want to leave one stock spring as a reference. 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. If you have trouble installing the springs try rotating them. Make sure all the springs are installed

correctly and the outside clutch arms are sitting flat. Install the metal plates and the e-clips. You will have to push

down on the outside plate to install the e-clips. Slide the clutch basket back onto the machine. Install the nut and

torque it to 94 ft/lbs, if it was peened over be sure to peen it back to lock it into position. 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. Bolt on the clutch housing and any other brackets that were removed. Push the back half of the primary clutch back

onto the shaft. Put the secondary clutch on; make sure it slides on all the way. Torque the nut to 83 ft/lbs. Thread

one of the clutch cover bolts 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 bolt and spacer. The clutch should slide all the way back

easily. If the clutch doesn’t seem to go on far enough to tighten the bolt 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 bolt and torque it to 85 ft/lbs.

Remove the bolt that was threaded into the secondary clutch.

11. Assemble the clutch cover and gasket. Install the metal foot rest bracket and plastic foot rest.

12. Install oil drain plug. Refill your engine oil to the proper lever according to owners manual. You can reuse your oil

if it was clean and was drained into a clean container. Only use manufactures recommended oil for proper engine

and clutch operation.

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.

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High-lifter Outlaw Super Duty Extreme Clutch Kit for Suzuki Ki User Manual Page 2

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