Outlaw Clutch Spring Kit Instructions For Honda ATV’s

High Lifter Products, Inc.
780 N Professional Dr Shreveport, LA 71105
1-800-524-2270
Outlaw Clutch Spring Kit Instructions
For Honda ATV’s
Models:
350 Rancher TRX 350 TM/TE/FM/FE 00-02
400 Fourman TRX 400 95-03
450 Fourman S/ES TRX FE/FM 98-03
500 Rubicon TRX 500 FA 01-03
Kit Part # HLCKH350RN
Kit Part # HLCKH450FM-P
Kit Part # HLCKH450FM-P
Kit Part # HLCKH500RC
ATV’s can be dangerous. High Lifter has no control over the use of any part. High
Lifter expects the customer to exercise good judgment as to the proper selection,
installation, use and maintenance of any part. Neither High Lifter Products or EPI
accepts any responsibility for damage to property including OEM parts or personal
injury 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.
Tools needed to install clutch kit:
Set of metric sockets
27mm socket
Phillips and flat tip screwdrivers
Torque wrench
Spring tool or needle nose pliers (45 or 90 degree bent pliers work well)
½” impact wrench
5mm allen wrench
Honda motor oil or equivalent
Honda 500 clutch tool 07ZMC-HN2A100 REQUIRED for Rubicon only
Honda Clutch tool #07933-HB300A or EPI #PCP-11 (An alternative to these tools
would be a gear puller see photo at end of instructions)
Gasket for Honda 400/450 provided in kit.
Liquid Gasket for Honda 350 & Honda 500 provided in kit.
Note: If you use the type of puller illustrated in the picture be advised not to warp the
clutch housing. If the clutch does not come off the ATV easily STOP and obtain the
Honda or EPI tool. If you over torque a stuck clutch with the gear puller you can warp
the clutch housing. The gear puller illustrated will not work on the Honda Rubicon.
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Installation
1. Remove the key from the ignition switch. Remove the left and right side lower
front fender by using two flat tip screwdrivers to pop off the plastic darts.
Remove four bolts holding the plastic engine cover on the right side of the
motor.
2. Remove the oil drain plug from the motor; if you can carefully drain the oil into
a clean container you may be able to reuse it, but if there is any chance of
contamination or if it is dirty change the oil and filter. Loosen and remove the
oil lines on the front of motor (5mm allen wrench). Note line location for proper
reassembly.
3. Remove the plastic shield for the front drive shaft by removing the two plastic
darts and one bolt. Remove the right side front inner fender well. Remove the
front crankcase cover bolts; keep track of each bolt length and location. Do not
loosen or remove tension adjuster nut on front crankcase cover.
Note: Tension adjuster on Honda 350/400/450 only.
There is no adjuster on Honda 500.
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4. Slide crankcase cover off slowly. Watch for internal parts inside the cover on
the left side of the machine so you know how they go back on. You may need
to loosen the rubber boot on the front shaft for enough clearance to slide cover
off. Watch for a washer lying inside the cover when removed, it will normally
stick to the cover or will remain sitting on the small shaft lever.
5. Using an impact wrench and 27mm socket remove the nut and washer in the
center of the clutch. Turning the nut in a counterclockwise motion.
Using the Honda, or EPI tool, or Gear puller, pull the clutch and outer housing off
the machine. There is a directional bearing in the clutch housing. If bearing is
removed or falls out make sure arrow on the bearing is going the right direction,
counter clockwise with the arrow on top, facing out. This bearing does not need to
be removed. Slide clutch out of housing and place on a clean work surface.
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6. 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 other end of the springs. Install the furnished springs by
inserting the spring into the outer edge first. Using a spring tool or pliers (45 or
90 degree) 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 to
watch the clutch arm is flat. Occasionally when you put the springs on they will
pop up. Slide the clutch into he housing and then slide housing onto engine.
Install washer and nut and torque to 87 ft/lbs.
Note: For each clutch kit there is a differing amount of springs and they are color
coded for each kit. See the chart for the appropriate application.
Spring Chart
ATV
Springs Per Kit
Honda 350
4 springs
Honda 400/450
5 springs
Honda 500
6 springs
Color
Black
White
Green
7. Thoroughly clean the gasket off the cover and the crankcase. Install new gasket
or liquid gasket and the crankcase cover. Slide crankcase cover on slowly
making sure all internal parts line up properly. Make sure you put the proper
length bolt in each hole. Torque bolts to 9ft/lbs. If you over torque they can
break.
Note: For Honda 350/500 use the liquid gasket material provided in the kit and
follow the instructions on the tube. Do not substitute gasket material.
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8. Install the plastic drive shaft cover. Install the oil lines; make sure the o-rings
are in place. If oil leaks where the lines go into the motor you are missing an oring or have a damaged o-ring, or if it is not sealed properly. Install the inner
fender well, both lower fenders, and the plastic motor guard onto the machine.
9. Install oil drain plug. Refill your engine oil to the proper level according to your
owner’s manual. Only use manufacturers recommended oil. Be sure to double
check oil levels after the machine has run for a few minutes.
10. Check for leaks. If your performance does not seem right double check to make
sure everything has been done properly.
Note: If you use the type of puller illustrated in the picture be advised not to warp the
clutch housing. If the clutch does not come off the ATV easily STOP and obtain the
Honda or EPI tool. If you over torque a stuck clutch with the gear puller you can warp
the clutch housing. The gear puller illustrated will not work on the Honda Rubicon.
Gear
Puller
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