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Posted by: kscowboy May 18 2005, 09:17 PM

i installed my clutch kit on my 05 500 manual today. I tried to take as many pics as i could. It takes about 2 hours start to finish. I am not totally done yet because i tore my gasket. I originally didnt order a new gasket because i thought i could get it off without tearing the old one. I would go ahead and order the gasket if i were to do it all over again.

This isnt a simple process but it isnt hard either. Just take your time and do it right. ANd make sure you reassemble everything just as you took it off.

Start off by removing the floorboard. You will have to drill out the plastic rivits because they cant be reinstalled
I almost forgot you need to drain the oil. The drain plug is on the bottom of the motor. There is a slot cut out of the back of the skid.

Posted by: kscowboy May 18 2005, 09:20 PM

Next you need to remove the clutch housing cover, disconnect the two water pump hoses and remove the oil filter.

Posted by: kscowboy May 18 2005, 09:25 PM

Remove the 5 e-clips to get to the 5 little clutch springs. When you get the 5 e-clips off you will get to 3 plates. Remove the plate and remember how they came off. They need to go back on exactly as they came off. Under the 3 plates is the clutch with the "Target springs".

Posted by: kscowboy May 18 2005, 09:29 PM

You need a good pair of needle nose vice grips and a 8 to 12" long flat tip screw driver. Grab one one of the springs and pull it out of place and reinstall. The purple one is the new one. You can use the screw driver to pry one end of the spring out. THis step takes about 20 minutes.

Posted by: kscowboy May 18 2005, 09:33 PM

THis is just another pic of how to remove and install the springs with the vice grips.

Posted by: kscowboy May 18 2005, 09:35 PM

wahla!! FINISHED PRODUCT

Posted by: kscowboy May 18 2005, 09:40 PM

This is a pic of the 3 plates that need to come off to get to the springs. You can also see the little clamping vice grips and a pair of chanel locks to hold the brake lever out of the way. You will need to disconnect the brake plunger at the back of the peddle. All you have to do now is reinstall the gasket and housing cover and fill up the oil and new oil filter. The cover will need to lign back up very correclty. There are 2 things inside tha fit into grooves in the cover.

Really pretty easy process. Probably about 2 to 3 hours for a hill billy like me.

Posted by: Scott F May 18 2005, 09:47 PM

Very good info for the guys with the 500's.

Posted by: SLP40 May 18 2005, 09:56 PM

im scared!!!

Posted by: GoFastCat May 18 2005, 09:57 PM

Wow, excellent write-up kscowboy

Maybe another member can do a similar post (with pictures) for installing clutch springs for an auto tranny. Also a full report for the stock exhaust mod would be another good one since these are a couple of common "how is it done" questions

It's pinned so the good info doesn't get lost.

Posted by: kscowboy May 18 2005, 10:05 PM

Thanks for pinning it. I think it should help anyone who want to try it.

SLP-No need to be scared. Im not an atv mechanic by any means. If i can do it i promise you anyone can. Really not all that hard.

Posted by: LittleCat May 18 2005, 11:17 PM

Excellent post Cowboy!! Great detail. I look forward to a detailed report on the performance gain once you put a ride or two on it.

Posted by: Bucanoles May 19 2005, 08:47 AM

ksCowboy, That tech write up is fantastic ! I wish there was a write up like that for all of the mods. I feel confident I can do this myself now.

What kind of SOTP performance gains did you get?

Oh BTW: Where did you get the kit? PN?

Posted by: kscowboy May 19 2005, 04:30 PM

The kit comes from EPI. I tried dalton but they dont make one and neither did epi but we talked them into doing it any way. The kit is $49.99 plus shipping.

This weekend will be the first ride i get on it. DMR, GWC and me all have the same bike except DMR has a kit in his. We all rode together 3 weeks ago and in the really, really thick gumbo mud, you could tell that DMR could turn his tires better than gwc and me. It just raises the engagement rpm's. Great for mudding

Posted by: ProComp May 19 2005, 04:36 PM

Nice write up! As soon as I get my pipe/jet mod installed and perfected, maybe I'll tackle this.

Posted by: kscowboy May 19 2005, 05:09 PM

Pretty easy to do. Just take your time and everything is self explanatory.

Pro-You got the part # to post on here. Mine is somewhere in the shop

Posted by: jimscat May 19 2005, 09:01 PM

Is the tranny the same as my 400?

Posted by: DMR May 20 2005, 09:06 AM

My Springs R GREEN, wander if their the same pressure???????Later

Posted by: SLP40 May 20 2005, 10:09 AM

I am still scared!

Posted by: kscowboy May 20 2005, 09:40 PM

I would like to know the same thing. I started mine up today after getting the new gasket in and filling it up with oil and just moved it forward about 2 feet and then back. It really revs up before it moves. It really moves the engagement rpms up. Cant wait to get it in the mud. I really think this is going to be great for mudding

Posted by: ProComp May 20 2005, 11:28 PM

WE490515 for $49.95

Posted by: kscowboy May 23 2005, 09:34 PM

**UPDATE**

I got to ride it this weekend . The purple springs really raise the engagement rpms. DMR has the green springs in his manual that are out of the auto kit. I think his engagement is raised about 200 rpm's and mine is about 500. I really like this kit. We were in some very nasty THICK turd this weekend and i had no trouble spinning my 29.5's. I was also able to back out of some very steep thick holes that i wasnt able to back out of before. The holes that i had tried before seemed easier. You just get more rev before it engages. Well worth the $58.

Posted by: texas27 May 25 2005, 11:56 PM

which kit has the green springs and which one has the purple etc?

Posted by: kscowboy May 26 2005, 09:03 PM

Some ppl have used the kit that is made for the auto. Just using the 5 little springs. The green ones come in the auto kit and the purple ones come in the actual manual kit.

Posted by: ac500 May 30 2005, 11:43 AM

Who did you order it from.

Posted by: kscowboy May 30 2005, 12:21 PM

EPI!

Posted by: ac500 May 30 2005, 08:25 PM

Thanks I did a search earlier and couldn't find it, but I found it. I just ordered it so I will be getting it soon I hope. Thanks Again. Now I just have to do it.

Posted by: Jakerolet Jun 8 2005, 06:38 AM

will the same kit work on the 400 and the 500? Also do you have a web site for EPI? Need the kit bad with 28" EDL's on a 400!

Posted by: LittleCat Jun 8 2005, 07:12 AM

'Sposed to work on the 400 as well. Looking into it myself.
http://www.erlandsonperformance.com

Posted by: Jakerolet Jun 8 2005, 09:38 AM

I just ordered the kit for the 500 manual; we will see if it works for the 400 man. I really need something to get off idle, I can keep them spinning if I ever get it above 2500 RPM's.

Posted by: trigger Jun 9 2005, 02:39 PM

great info and the pictures help even more
thanx

Posted by: Jakerolet Jun 20 2005, 01:21 PM

Im putting mine in tonight! We'll see how it goes in a 400! Wheelie maybe?

Posted by: Jakerolet Jun 21 2005, 06:10 AM

did it last night, really not that hard. dont know how its going work out, it just feels wierd. Its like it has a 4000 stall converter in a drag car! Still no wheelie

Posted by: ac500 Jul 3 2005, 11:04 PM

Well can you spin the EDL's better now. I just bought some 28" EDL's also and I have the kit ready to put in. Just wanted to see what yawl think about the clutch kit first before I do it. Do you think the green springs would be better than the purple.

Posted by: Jakerolet Jul 4 2005, 04:12 PM

The biggest advantage i have seen is when I know the hole is coming up, like at a mud sling, I turned up the idle to just before it started to pull, when you get to the starting line you just snap the throttle and there is no lug or delay, just rooster tails! I may try the green springs because the purple is what I would consider compatition only, not much fun to just play on trails. It is a big help though to turn the big heavy edls.

Posted by: ProComp Jul 6 2005, 10:18 AM

Good feedback guys. Ya got me thinking. Maybe we should contact Erlandson about a second kit. One with green springs and one with purple. One could be called a trail kit and one a mudder kit?

Posted by: ac500 Jul 6 2005, 09:48 PM

Sounds like the green springs are the way to go for trail and mud riding. Then for a mud bog maybe the purple springs are better. I was just wondering the 500 manual in low wont turn 28" tires? I have 27" soon to have 28" EDL's. Do you realy need the kit for these tires? With the kit has anyone broke a CV yet? I have already bought the purple kit now I have to think of what to do. Just a few questions.

Posted by: Jakerolet Jul 7 2005, 11:25 AM

I think you should be able to turn them with the 500. The kit can only help though. I am only able to turn mine with the 400 because of the kit. As for the CVs, it should have no effect other than the invisibe root you may be able to turn your tires on that would have ordanarally stalled the motor down. Im going to get the green springs from DMR so I can give a side by side comparison.

Posted by: B_Brown Jul 21 2005, 05:32 PM

hey man, that seems easy enuf, as soon as i get around to it, thats my next mod, thanks for the great info

Posted by: gsheehan Aug 25 2005, 05:13 PM

Guys, what did this do to the top speed of the 500 manual? Does this work for the 2003 500's too?

Can you make this mod on a 500 Automatic? This is a separate upgrade from the CVT springs and weights right?

Posted by: Howard Sep 2 2005, 07:21 AM

They do have these for auto's
http://www.erlandsonperformance.com/new/ATV-shop.php

i doubt this will effect top speed, this just changes the clutch engagement RPM.

Posted by: Muddedprairie Sep 2 2005, 04:25 PM

This is the firsttime i read Ks's post on this... I did this to my 03-500 manual and i like it alot... I'm running 29.5x12's on all coners and i will post a pic of our last mudbog.. The mud was so deep you coulden't see the back of the quad when i'm comming out of the mud... Was REAL THICK and SWAMPY!!! but what a blast... This mud stopped most all 650 honds... Not enought power in them in this type of mud... I have and will keep the purple springs in it... Even plowing snow... This will be my first year plowing with the kit in.. It can only help.

Mark

KS, Very good detailed instructions.

Posted by: ProComp Sep 8 2005, 08:56 PM

Got mine installed tonight. Wasn't too bad a job just make sure when you take off the cover your careful as there are some pieces in there that can fall off. It seemed they only went back on one way so I was luck.

Anyway, be careful the gasket goes on properly as mine some how got caught up some how and leaked. Had to take it off and lucky it went back on and is not leaking right now. There is one dowel pin on the motor side and one on the cover side? What was Cat thinking? 2 on one side would have held the gasket in place nicely?

Anyway, its a lot mellower than I thought it would be. I thought it would really rev up and come in hard but it doesn't.

Now I just need a pipe set up I can live with!

Posted by: Muddedprairie Sep 9 2005, 05:53 PM

Procomp,

What springs are you running the purple or green?


MArk

Posted by: Howard Sep 10 2005, 07:18 AM

yeah were did you get yours from and what springs? green or purple. i want a kit but somethign that doesnt rev real high and kick into gear hard.

Howard

Posted by: ProComp Sep 10 2005, 10:45 PM

Got mine from EPI. Purple springs. Quite a bit bigger than stock.

Posted by: Muddedprairie Sep 11 2005, 02:13 PM

Yes i have the purple also..

MArk

Posted by: ssjrmk Sep 15 2005, 02:48 PM

Procomp I was wondering if you could tell me a little more about how the springs are working for you. I have the same set up as you, so i am just wondering if i should do the change?

Posted by: ProComp Sep 15 2005, 03:02 PM

I thinks a good improvement for the money however I thought it would be more noticeable. It does seem a lot more noticable in reverse. The springs are quite a bit beefier so it definately upped the engagement which is what you want with bigger tires. That help?

Posted by: dezfan Sep 18 2005, 01:32 AM

Great write up! Now we need one for the 650 auto!

Posted by: JAKE JANACEK Sep 19 2005, 06:40 PM

Any of you guys ever used the orange springs? If so how do they compare to the purple and the green. I had the orange ones in my 03 500, nasty stall with those.

Posted by: DMR Sep 19 2005, 06:46 PM

Jake.....Where did u get the ORANGE ONE'S?????????????? Also have u thought about makin the Gear Reduction for the Manual Cats???....Later

Posted by: JAKE JANACEK Sep 19 2005, 09:19 PM

The orange springs are some that I pirated from an Old school clutch kit. They have some nasty stall. I can get more orange springs too. I plan on addressing a gear reduction for the 500 manuals when I finish up the 500 foreman and rancher 350 first.

Posted by: Muddedprairie Sep 20 2005, 11:44 AM

Jake,

Did the orange ones make a difference in the thick stuff?.. Also i must say that the purple ones do have a great stull effect... I know the engin braking was improved... Wold like to try the orange ones.. Were do i sign up?

MArk

Posted by: JAKE JANACEK Sep 20 2005, 05:11 PM

I can get more orange springs, but I can only buy them 400 at a time. that gets pricey. And I dont know if they have more stall than the purple or green.

Posted by: DMR Sep 21 2005, 08:30 AM

The Purple Springs have more Stall then my Green Springs.......We figured the Green had roughly 200-300 Rpm stall and the Purple roughly 500 Rpm.........But I have turned my 29.5's with the Green Springs where Ks could turn his 29.5's with the Purple and couldn't where he couldn't turn his......So If u understand that?????

What do u think the Stall is on the Orange Springs......Later

Posted by: Muddedprairie Sep 24 2005, 04:54 PM

I'd be willing to try the orange ones... Where do i get them? JAKE?

MArk

Posted by: MudFly Oct 19 2005, 08:47 PM

I checked out the website and noticed two kits. One with part number WE490515 and one with WE491050. The first is labeled as sport utility and the other competition. I am correct to assume the sport utility is the the green and the comp is purple? I would like to try these out. I have a set of 26" ITP 589's and it seems sluggish at times. How would they effect plowing snow?

Chad Ruehl
Oxford, OH
04 500i Manual
26" ITP 589's
ITP C-Series Type 5 wheels
all kinds of custom extras

Posted by: LittleCat Oct 19 2005, 09:04 PM

to MudFly!! If you get no reply soon, try PMing a few of them. I'm sure these guys will answer your question.

Posted by: kscowboy Oct 20 2005, 08:24 PM

mudfly-Sorry man but i dont know which one i bought. A couple of us decided to get epi to make these kits and told them there was a real need for them and they did it. So i called them and bought the first kit they had done. I dont know the number but if you call them they can tell you the color of the springs.

Posted by: ProComp Oct 20 2005, 08:29 PM

WE490515 - purple (competition maybe?)

I'm guessing the other number is green (sport utility?)

KSCowboy - your ever feel like it slips? I think what happens if you shift at too slow of rpm with the clutch kit, perhaps the rpm is too low and it has to rev up to engage again. Or maybe my clutch is getting worn with 3100 miles on it?

Posted by: kscowboy Oct 20 2005, 09:20 PM

No mine never feels like it slips. But i dont have 3100 miles on it. Hell im lucky if i have 20 miles on it. But i only mud, and have been pretty busy this year so i havnt got to do a whole lot. BUt i also adjust my clutch. I have done this twice. Mostly for the hell of it but i dont think it hurts.

Posted by: kscowboy Oct 20 2005, 09:21 PM

But even with that many miles on it i cant see it wearing out. But maybe im wrong

Posted by: Muddedprairie Oct 22 2005, 12:34 PM

I have the kit.. And i also have an 03- with only 585 miles on it.. Got to ride only 1-thine with the kit and i think it made a difference (purp springs). Heres a pic of mine and what the kit is working.. I also have the web cam with helped out also.

Mark

Posted by: ProComp Oct 22 2005, 04:26 PM

How do I adjust the clutch? Its probably never done!

Posted by: kscowboy Oct 22 2005, 07:27 PM

its in the repair manual. I can post it in the morning. Its in my shop so i will go get it in the morning. Its really easy though

Posted by: kscowboy Oct 23 2005, 10:56 AM

Here is how you adjust your clutch

Posted by: ProComp Oct 23 2005, 11:07 PM

Thanks!

Posted by: MudFly Oct 24 2005, 09:07 AM

ProComp,

Are you saying you know for sure that the WE490515 kit contains purple springs?

I am still not sure which one I am going to get. Was actually leaning towards the green. They are not as stiff as the purple, right?

Posted by: AC650 Oct 24 2005, 11:37 AM

I was thinking of the green as well. I think they are from the Auto version though and that kit is $200. Anyone checked to see if EPI will sell just the green springs?

Posted by: ProComp Oct 24 2005, 03:35 PM

Several of us approached EPI to make a manual kit as we were having to buy the auto kit, use the springs and sell off the rest. They agreed and came out with the one I referenced above. It was the only one available when I ordered and the springs were purple. I have no knowledge of a second kit. Just phone and ask them when you order. Its possible its the green ones from the auto kit I guess.

I wouldn't go with anything less then the purple. There not that aggressive.

Posted by: MudFly Oct 25 2005, 11:49 AM

OK, I just dont want to get too aggressive. I do not do any serious mudding or anything. I mostly use it around those house pulling trailers and such, plowing snow, and other odd stuff. I am hoping these will help out plowing snow mainly.

Posted by: ProComp Oct 27 2005, 10:15 PM

Well I just did the clutch adjustment and I didn't really have to do much. The screw on the right was pretty difficult to turn. The instructions say turn it all the way counterclockwise and it did finally go but not that easy. Hope its OK.

The smaller screw on the left turned both ways easily like the instructions indicate it should.

Posted by: kscowboy Oct 28 2005, 08:17 PM

Yeah theres not much to do for this adjustment. Im not sure how it actually does what it does but it does work. We tried to adjust GWC's right before a mud bog competition and we had it so screwed up it wouldnt move, at all. So after we got the manual out of my truck we finally got it right. But mine was really easy to adjust and GWC's was very very tough like yours. Not sure what the difference is but you have done it correctly.

Posted by: ProComp Oct 30 2005, 05:06 AM

Had to go back and do it again, quad barely moved! This time I took screw number 2 and went clockwise until it got real easy and then went counterclockwise until it stopped and then went the 1/8th turn. I think it was tight, all the way counterclockwise when I started the first time?

Anyways guys, this was just to tell you that both screws should turn relatively easy and you should not have to force them. Works great now and the clutch kit is more noticeable with the clutch set properly.

Posted by: MudFly Oct 31 2005, 09:29 PM

It says to turn #2 back and forth to ensure free movement. Question I have is where do you stop? Does it matter or does it just need to be loose? ProComp, did you set both of yours in 1/8 turn? I know it says to set #1 at an 1/8 but says nothing about #2. Just curious before I dive into it. I will be ordering my springs, putting them on and then adjusting it.

Posted by: ProComp Oct 31 2005, 10:28 PM

My instructions are in the garage but I think you have your numbers mixed up. Loosen both nuts. Check #1, the one on the right to insure it moves back and forth freely. I did that and left it in the same spot. I then went to number 2 and
went to turn it counterclockwise and it wise tight and felt like it was kind of grinding. So, the best way in my opinion is start by turning this one clockwise and it should be REAL easy like number one. Turn it gently counterclockwise after that. You'll know right away when it get tough. Turn it back clockwise 1/8 turn and tighten the lock nut. Mine works better then it ever has.

Posted by: MudFly Nov 4 2005, 07:53 AM

Well, I got my springs (purple). Only thing is, I cannot find anyone that has the gasket in stock. Do any of you folks know where I might find one in stock?

Posted by: ProComp Nov 4 2005, 09:52 AM

try.www.brownsleisureworld.com or maybe www.rvsports.com. They both do a lot of mail order. Ones in Canada and ones in the US.

Posted by: MudFly Nov 4 2005, 10:27 AM

Cool, thanks. rvsports had 2 in stock. Mailing one out today.

Posted by: cmepoo Nov 15 2005, 05:33 PM

They offer 2 different kits we490515 & we491050 as posted eariler. I called them and the lady on the phone said thet she would not tell the color of springs. I told her that I wanted the purple springs, and she still would not help me, whats up with that. Hope that I can get help here at this site. I can only ass u me that the comp. kit for $99 is the purple springs.

Anybody can email me if they know.

Posted by: MudFly Nov 15 2005, 05:46 PM

I just got the 49.99 kit and they are purple.

Posted by: rbreak Nov 27 2005, 12:33 PM

Hello, would this kit do anything for keeping the clutch from slipping at higher rpm's? It sounds like it raises the lockup point of the primary clutch, my problem is the clutch slipping after it is supposed to be locked up (secondary clutch?). Are there any heavy duty springs/plates or kits for the secondary clutch? I looked on EPI's site, I couldn't tell for sure if they had anything for the secondary system. I'm new to all this clutch stuff, so I may be missing something obvious. Sorry for all the questions, my clutch started slipping on me yesterday and I am trying to learn what I can as fast as I can to get it fixed. And thanks for all the excellent information already posted, I have learned the most from this site (I'm also posting on highlifter). Thanks in advance for any help or response.

Posted by: rbreak Nov 27 2005, 02:32 PM

O.K. I did a little more research on the epi website, I saw where others had stated they offer two kits (we491050 @ $99.95, we490515 @ $49.95). It isn't very clear whats what from the site, but mudfly got the purple's with the we490515 kit so at least that should be figured out.

One thing I wondered about, in the suzuki section for clutch info, they had what appeared to be the same spring kit as the we491050 for the same $99.95 price, it was for the LTF500F motor which is the same motor as the artic cat, but it had a different part#, we394020. Seemed odd, I wondered if there was yet a third spring rate option. I was going to e-mail epi but it states in caps by their e-mail address that they do not respond to technical questions (wierd), and from the sound of cmepoo's post they don't help much on the phone either, so it may stay a mystery I guess.

One more thing, I found they do offer a clutch pack kit (friction plates/steel plates/heavy duty springs) for the vinson 500 manual so it should be the same as the artic cat 500 manual. If anyone ever toasts their clutch they might look there for help. The part # is we150187 for $94.95. I think I'm going to order it along with the we490515 purple spring kit.

Posted by: DMR Nov 27 2005, 04:47 PM

I have the green springs in my Cat........Which I like alot.....Most people I know R running the Purple Springs and that KIT costs 49.95 plus shipping.....But Highlifter sell the same Kit,but somes with a GASKET also........later

Posted by: AC650 Jan 16 2006, 10:07 AM

Dose anyone have the part # for the gasket?
I just ordered the springs and want to order the gasket (just in case)
Whats the best place to order the gasket?

Posted by: ProComp Jan 19 2006, 01:33 PM

gasket will have to come from an AC dealer.

You can pull up part numbers on www.brownsleisureworld.com or something like alphasports in the US.

Posted by: Muddedprairie Jan 21 2006, 07:26 AM

3402-538

Is the part number for you quad..

MArk

Posted by: DOZERCAT Jan 23 2006, 04:17 PM

thanks alot kscowboy for the guide through the clutch install. did it this morning and it went great. thanks again

Posted by: kscowboy Jan 23 2006, 09:44 PM

no problem. I have learned a ton off this site and it is the least i could do.

Posted by: Muddedprairie Jan 24 2006, 01:34 PM

I think we all have learned more from this site then we ever thought we would.

MArk

Posted by: XLCat Jan 31 2006, 10:06 AM

I called EPI about the clutch springs. No way no how would they tell me what color was in what kit. No way no how would they sell me only the centrifugal clutch springs out of the auto kit. I told them they missed a sale and they would still not work with me. I don't want the full stall of the purple springs (400-500rpm). I just want maybe 200 (green springs from auto kit), but I'm not giving $100 for the auto kit and use half of it. EPI is definitely not willing to work with anyone on this.

My next approach is to tell them I ruined the springs while installing them on my auto and that I need replacements. Maybe they'll work with me if I lie to them.

Posted by: ProComp Jan 31 2006, 10:14 AM

Well it was like pulling teeth to get them to put a manual kit together and it was a no brainer. Thing of the profit on 5 springs for $50 bucks.
Go with the purple springs, you won't regret it. To be honest, I thought mine would come in higher then it did. When I put Kodiak springs in my Bruin in made a way bigger difference.
Especially running 28's. Go purple. The auto are green.

Posted by: gwc Jan 31 2006, 04:08 PM

yep just get the purple ones,i put mine in Saturady took 2 hrs start to finish,got my kit from HL and it came with a new gasket its more money but did not want to wait on the gasket from the dealer! wish i would of not waited so long, these springs sould come in them stock.lol

Posted by: AC650 Feb 2 2006, 03:32 PM

Don't worry about the stall. I hardley noticed any diffrence after installing mine. They did help with turning the 28x12 Outlaws though. I'm going to 29's now. I hope they are enough.

Posted by: Muddedprairie Feb 2 2006, 08:15 PM

Garrette,

You just went to the springs now... Thought you had them all this time... Boy am i happy with mine.... I love them..Woulden;'t go back to stk springs ever!!!..

MArk

Posted by: gwc Feb 2 2006, 09:02 PM

yes i was not having any problems spinning my tires but thought for the money i should get them in,you never no when you will need just alittle more help. i really like the springs they should just come with them from the factory...

Posted by: adamdawe Feb 12 2006, 08:05 PM

so does the purple or green work better and does it work on the 400m?

Posted by: Camlocker Feb 14 2006, 01:26 PM

Was it ever determined which kit was what? I would like to go with the Green springs since I don't have that much loss in power. I looked at their website this morning and did notice two kits.

Does anyone know if EPI even offers a kit with the green springs? If not, are you sure that the automatic clutch kit has these green ones in it?

I guess I just don't want to hemhaw around and get the wrong kit.

Posted by: gwc Feb 14 2006, 03:18 PM

i would just the $49 kit with the purple springs the $100 kit has the green ones i was told..

Posted by: adamdawe Feb 14 2006, 07:31 PM

does the kit work on the 400

Posted by: Camlocker Feb 15 2006, 08:51 AM

Adam, they do have a clutch kit for the 400.

02-05 400 Manual-Any size tires part# WE490425

Don't bother calling them, because I got the same result as XL Cat. They will not tell you anything besides that the kit is designed for the model specified. They also informed me that the sport utility kit raises the engagement point 400-500 RPM whereas the competition kit raises it from 900-1000 RPM. Other than that, just phone static.

I'm looking for the green springs which raise it 200-300 RPM like KSCowboy is describing. If they only come with the automatic kit, I'll spend the extra dollars to get what I want. Too bad they don't want to cooperate like I was hoping for.

KC

Posted by: DMR Feb 15 2006, 09:46 AM

I got my Green Springs that I had in my 500M from a 500 Auto Kit.....I had No Problems turnin my 29.5-10's with them.....Could turn them everywhere Kscowboy did with the Purple Springs......Reverse is the ONLY DOWN SIDE of the 500M..........

Posted by: Camlocker Feb 15 2006, 10:13 AM

Thanks DMR. That's what I needed to hear. Looks like I'll be ordering the auto kit.

Posted by: Muddedprairie Feb 15 2006, 10:23 AM

I though the 05's had the low range rev... Like mine dose?...

MArk

Posted by: gwc Feb 15 2006, 08:54 PM

they do same motor but reverse is not the same as first gear it is just a touch higher ( if you look at the tranny break down you can see the gears are diff size with rev being just alittle bigger) and in really really thick mud the 500 will have more trouble spinning the tires in rev the in forward.... but mine is yet to bogg out in reverse allways getitdone

Posted by: Muddedprairie Feb 16 2006, 07:23 AM

GArrette,

I agree......

Posted by: DOZERCAT Feb 17 2006, 10:55 PM

HAS ANY BODY USED A LIFT KIT WITHOUT USING GORILLA AXLES. AND IF SO DOES IT MAKE IT WEAKER. ALSO HOW DO I PUT A PIC NEXT TO MY NAME ON THE BOARD.

Posted by: Muddedprairie Feb 18 2006, 11:22 AM

Dozer,

When i first put my 3-inch lift on i didn't have gorillas at all.. And i broke a few axles... Then i went to the updated 04-axles in the frt and Gorillas in the rear... And (Knock on Wood) so far so good.... I think if you go with a 1 inch you will be ok...

MArk

As for the pic.. Go into your settings and follow the promps to do it.

Posted by: QUADNUT Feb 25 2006, 01:10 PM

I can get my hands on the springs for a kingquad clutch kit that the guy ended up not using and sold the quad. Will these springs fit in the clutch the same as the other ones?? I would have the springs given to me so its a no brainer since i plan on ordering 29.5 tires for the vinny. can anyone running swaplites tell me the actual width of them? i want to run them on front and 10" laws on back. the laws are roughly 9 3/4" and i dont want the lites wider than my rear tires. I thought the springs in the auto vinson kit were plenty high enough stall speed. Can wheelie the vinny with 27" laws on it.

Posted by: Muddedprairie Mar 2 2006, 05:27 AM

The springs will work..

Can;t answer your question on the tires..

Mark

Posted by: ProComp Mar 20 2006, 01:47 PM

I see EPI has "COMPETITION SPRINGS" anyone try that kit yet?

What is or was the color that came originally in the 500 auto kit? Just trying to keep the colors straight. I thought they were green as well but the purple ones came in higher?

Update - not sure on color but the green in the auto are said to raise engagement about 200 rpm, the purple in the standard kit for $49.99 is around 500 and the $99.99 kit raises it up 900-1000rpm.

Posted by: Muddedprairie May 15 2006, 06:23 PM

I have the purple springs in mine and i'm happy with them.. I do belive they made a difference.

Mark

Posted by: sylvain Aug 15 2006, 10:07 PM

do you think the same kit would fit a 400 manual its also an 2005 ???

do you think the kit will fit the 05 400 manual ???

Posted by: oleblue Sep 29 2006, 06:54 AM

Ordered the kit for a 400 manual oversize tires the other day. Well in came in last night and I took me a couple hours but she's in and I like it. They sent me the orange springs, the stall is not all that crazy like some said on here. Maybe it depends on the bike?? Took me the longest to scrape off the old gasket with a razor. Pretty easy mod all together. Thanks KS for the pictures.

Posted by: Fast 440 Sep 29 2006, 07:10 AM

I have a set of orange springs from EPI if anyone is interested PM me!

Thanks

Fast

Posted by: cheech Jan 16 2007, 01:19 PM

by getting a clutch kit for my 05 400 man. will it help it turn in reverse when I am in thick mud...??????

Posted by: stihl Jan 19 2007, 05:55 PM

I have a 400 auto. Is this basicaly the same? I am looking for more power from my clutch. What about the spring? is that difficult?

Posted by: bullridin_fool Jan 23 2007, 08:24 AM

would it be possible to get some dimensions on these springs. i don't care if it's the stockers, the green, purple or even these orange ones i read about.

i need
overall length(including the hooks)
the outside diameter
the diameter of the wire that the spring is made of
and if ya have anyway of measering it---- how many pounds does it take to start seperating the spring.


if i can get all of this i think i might be able to get these springs alot cheaper than, the current supplier. they're not actually making the springs, there buying them from somebody else then raping us $10 a spring. if i can match up the springs i should be able to get the set for $10.

Posted by: ArcticTRV Mar 3 2007, 07:25 AM

Hey does anyone know if the 2005 400 auto TRV clutch kit from EPI fit the 2006 400 auto TRV? Another thing.. Did anyone elses bolts that attach the front speedrack to front body panel vibrate loose or off? I'm missing both on the front. I think i might have to get some and locktite them or something. Does anyone have an exhaust on a 400 TRV as well?

Posted by: catlos Apr 11 2007, 12:47 PM

got my purple springs in, not much of a problem getting them in. havent gotten into any thick stuff yet, but so far i cant tell much of a difference. the stall is nothing like i thought it would be.

lass week i cood not spell MEC-uh-NIC. now, I is wun.

Posted by: stevenwf Apr 11 2007, 08:19 PM

After looking everywhere online I couldn't find a clutch kit for my 2006 400 Manual so I ordered the kit for the 2005 400 Manual. It was the orange springs. The install went great and I couldn't be happier with the clutch upgrade. So anybody with 06-07 400 Manual you can get the 05 400 Manual kit from EPI and it will work.

Posted by: GREY GOAT May 2 2007, 07:10 PM

I did mine today.......Boy was that fun!!!!

I will say this, make sure the DANG clutch weights are back far enough or you aint gonna get the cluth holding plates back on for the e clips. Its very simple with the new springs on-Just use a screwdriver and push between the weights and it will give enough to push the entire weight back towards the bike. Make sure they are all back. I fought this until my neighbor pointed out that one was further back than the rest.

The rest is a piece of cake.

If you have any assembly problems like stuff falling off, should only be about 3 or 4 things loose that would come off-check this for help http://www.brownsleisureworld.com/ you will have to click on the PARTS icon, then select ATV, then your YEAR and so on, then click the CLUTCH ASSEMBLY.

Good luck to others!

Posted by: GREY GOAT May 3 2007, 02:11 AM

Well guys, I goofed bad! Something kept bothering me as i sealed everything up and tightened the last bolt. I remembered the inner shaft that turns the impeller in the water pump housing had fallen. It free spun-not to its original position. I took the cover off the water pump housing and sure enough it was tick and tat, the impeller shaft inner rod was hitting the inner shaft.

I took the cover and all the bolts off, wripped the skin off my middle finger knuckle in the process and i managed to tear my new gasket. . By now im pissed off.

Now i had to order a new gasket, found one for 16 or so bucks plus shipping.

Heres my dumb question. The bike did not come with a gasket silicon sealer, do you guys think it needs it in addition to the gasket?

I have always done this before (intake manifolds and such) but this made a mess while trying to get the oil filter around the plastic fender well.

Posted by: mexhusky357 May 4 2007, 08:53 AM

did my clutch spring mod. it was cake. i went with the purple springs and couldnt be happier. i was a little worried before i put them in that the stall would be too high but its not at all. we do alot of trail and mud riding. this really helps my little 500 on 26's pull the hills also. if your goin to do this mod definitely get the purples. you wont regret it.

Posted by: yelladog Jun 7 2007, 09:41 PM

Hello All, New to the forum here, but been reading for awhile. Heres what I got. A buddy of mine has an 03 400 Manual with 26" Gators. The clutch has started slipping some so Im going to replace it for him. Ive done a few dirt bikes with hand clutch, but not one like this. Question is, should I be looking at replacing the plates and springs on the primary clutch or something with the secondary clutch??? Any suggestions, tips, etc would be greatly appreciated!!!!!!! Thanks

Posted by: yelladog Jun 8 2007, 03:28 PM

Any Ideas????

Posted by: Centexan Jun 17 2007, 11:31 PM

Anyone know the EPI kit number for an 07 500 man. Want the purple springs.

Posted by: GREY GOAT Jun 18 2007, 12:05 AM

\

Centexan, call highlifter directly, they will be able to help you...yes on the purple...

Posted by: kscowboy Nov 22 2007, 08:54 PM

I can only see 3 of the 7 pics. THe rest are just blank. ANyone else having this trouble or is it just me. Can anyone see all the pics?

Posted by: Bearcat 74 Dec 25 2007, 07:56 PM

Some of the pics are black for me as well.

Posted by: fox_kid_263 Jan 30 2008, 10:55 PM

I have a Vinson 500 M and I got the EPI kit for it and the springs I got are white?? Part number is WE493002.
I also got a EBC clutch plate kit thats comes with friction plates, steel plates and heavy duty springs. Part number DRC120. I'll be installing it tomorrow and taking a bunch of pictures.

Posted by: 400cat_f150 May 17 2008, 04:08 PM

Thanks K. Great post. Put the purples in my 400 today and love it.

Posted by: eregister May 18 2008, 12:10 PM

i missed som of the install pics, and the pic of adjusting clutch.

Posted by: Bearcat 74 Jun 3 2008, 06:26 PM

I put my High Lifter clutch kit in lastnight. It is the EPI springs with a gasket. It is not really that noticable and I agree with the people that say it should come in them stock. I can get both front wheels up in high 1st with no jerk on the bars, low 1st and set back a little and it'll really stand up.


Install took about 3hrs, the worst part was getting the cover off, and installing the springs. I had to get my BFH and knock the right side cover off and needle nose vice grips would work MUCH better than standards. Overall, it was worth the money and time for install.

Posted by: Louie2 Jun 10 2008, 04:43 AM

I installed the purple springs last night. I lucked out and was able to reuse my gasket. It i s noticable but nothing obnoxious. My advise is TAKE YOUR TIME!!!!!!


Does anyone know if the AMR coil is worth the $? Also can anyone explain the slide mod , Spring, and exhaust mod in depth? I have a 2'' snorkle and a k&n so far on my 2006 500 manual.Also what jets will I possibly need after these mods? Thanks alot this website is awesome!

Posted by: eregister Jun 25 2008, 06:22 PM

does anyone know if the cover needs to be torqued? if so, how much?

Posted by: cold cat 500 Jun 25 2008, 07:39 PM

MY 2006 Service Manual says to Torque them, 6.5-9.5 Foot Pounds.

Posted by: RedVinson Jul 10 2008, 06:01 AM

What about the Gasket for the Clutch Cover. Does it need to be sealed or not? Is it self sealing?

Thanks
Ron

Posted by: ArcticCatRider500 Jul 26 2008, 09:37 PM

hey im thinkin bout gettin an hmf fer my 500 how loud is it on yers???

Posted by: gmd940 Oct 11 2008, 11:08 AM

A very good post kscowboy, however, I could only see 2 of the pictures (005 and 007).
I know this is old stuff (2005), but if you still have these pictures could you email them to
me (geoff_dx@hotmail.com), much appreciated.

Posted by: CatKraz Oct 23 2008, 08:29 AM

A very good post kscowboy, however, I could only see 2 of the pictures (005 and 007).
I know this is old stuff (2005), but if you still have these pictures could you email them to
me (geoff_dx@hotmail.com), much appreciated.
[/quote]

Its very easy to do! well, the springs are a SOB, but its pretty straight forward. Once you do one, the rest of the springs come pretty easy.
Tha easiest way for me to do them (I dont have needle nose vice grips) was to take all the springs out first, and then install the new ones. I used a metal pick to run through the hangar part, and into the hole the hangar goes in. I then would lift up, which would stretch the spring and then use the but end of a screw driver to tap on it, and make the hangar splide down the pick, and into the hole. But I bet, the vice grip needle nose would be much easier!

take pictures of each one of the plates before removing them, with a digital camera, just in case you forget how they line up or which wat they go.

Also there is a small pin on the bottom right side that will slide out. Very easy to put back in, but just dont loose it. Watch out for the washer to on the bottom left. It will slide off, so make sure you dont loose it either.

Posted by: cold cat 500 Mar 19 2009, 12:00 AM

I will be Adding Purple Springs to Mine in a Couple more Weeks.

Posted by: cold cat 500 Apr 24 2009, 03:36 PM

I got My Purple Clutch Springs Installed Today, Wow what a Difference they Made, Purple Springs are what You want to Install. Ready to Trail Ride Now!

Posted by: dangerranger_04 Aug 24 2009, 10:33 PM

I have a 06 400 manual with 27" Mud Machine bi-claws and tri-claws. Would a clutch kit help any with the high a$$ reverse gear they put in these things? Would I need a clutch puller to install?

Posted by: nwngunner Aug 25 2009, 12:50 AM

Danger, i would just go with the reverse cam mod that is discussed in the other thread. There are videos of before and after. The after is amazing. I cant wait to get mine done, i just have to not be working 95hours every 2 weeks.

Posted by: dangerranger_04 Aug 25 2009, 06:43 PM

Has anyone that has done the reverse mod now how reliable it is? I mean its not gonna mess something else up. And thanks for the info nwngunner.