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Manual clutch kit install, with pics

kscowboy View Member Profile	May 18 2005, 09:17 PM Post #1
"ROCKS DON'T FEEL PAIN. BE A ROCK!!" Group: Members Posts: 570 Joined: 15-November 04 From: Freeman Missouri Member No.: 4283 Your ATV: 05 cat 500 man	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. Attached File(s) clutch_kit_001.jpg ( 34.67K ) Number of downloads: 445 -------------------- "THE ROCK" Team "GET-YOU-SOME" 05 Cat 500 manual FULLY SNORKELED Vent lines Re-Routed Radiator Relocated 29.5 Laws on type 7's EPI Clutch Kit HMF Pipe Dyno Jet Kit Gorilla Axles 25" of G/C and 4:10 Gears BUILT BY ODB CUSTOM ORANGE 500 CAT

kscowboy View Member Profile	May 18 2005, 09:20 PM Post #2
"ROCKS DON'T FEEL PAIN. BE A ROCK!!" Group: Members Posts: 570 Joined: 15-November 04 From: Freeman Missouri Member No.: 4283 Your ATV: 05 cat 500 man	Next you need to remove the clutch housing cover, disconnect the two water pump hoses and remove the oil filter. Attached File(s) clutch_kit_002.jpg ( 38.38K ) Number of downloads: 57 -------------------- "THE ROCK" Team "GET-YOU-SOME" 05 Cat 500 manual FULLY SNORKELED Vent lines Re-Routed Radiator Relocated 29.5 Laws on type 7's EPI Clutch Kit HMF Pipe Dyno Jet Kit Gorilla Axles 25" of G/C and 4:10 Gears BUILT BY ODB CUSTOM ORANGE 500 CAT

kscowboy View Member Profile	May 18 2005, 09:25 PM Post #3
"ROCKS DON'T FEEL PAIN. BE A ROCK!!" Group: Members Posts: 570 Joined: 15-November 04 From: Freeman Missouri Member No.: 4283 Your ATV: 05 cat 500 man	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". Attached File(s) clutch_kit_003.jpg ( 41.11K ) Number of downloads: 55 -------------------- "THE ROCK" Team "GET-YOU-SOME" 05 Cat 500 manual FULLY SNORKELED Vent lines Re-Routed Radiator Relocated 29.5 Laws on type 7's EPI Clutch Kit HMF Pipe Dyno Jet Kit Gorilla Axles 25" of G/C and 4:10 Gears BUILT BY ODB CUSTOM ORANGE 500 CAT

kscowboy View Member Profile	May 18 2005, 09:29 PM Post #4
"ROCKS DON'T FEEL PAIN. BE A ROCK!!" Group: Members Posts: 570 Joined: 15-November 04 From: Freeman Missouri Member No.: 4283 Your ATV: 05 cat 500 man	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. Attached File(s) clutch_kit_004.jpg ( 39.16K ) Number of downloads: 43 -------------------- "THE ROCK" Team "GET-YOU-SOME" 05 Cat 500 manual FULLY SNORKELED Vent lines Re-Routed Radiator Relocated 29.5 Laws on type 7's EPI Clutch Kit HMF Pipe Dyno Jet Kit Gorilla Axles 25" of G/C and 4:10 Gears BUILT BY ODB CUSTOM ORANGE 500 CAT

kscowboy View Member Profile	May 18 2005, 09:33 PM Post #5
"ROCKS DON'T FEEL PAIN. BE A ROCK!!" Group: Members Posts: 570 Joined: 15-November 04 From: Freeman Missouri Member No.: 4283 Your ATV: 05 cat 500 man	THis is just another pic of how to remove and install the springs with the vice grips. Attached File(s) clutch_kit_005.jpg ( 39.84K ) Number of downloads: 264 -------------------- "THE ROCK" Team "GET-YOU-SOME" 05 Cat 500 manual FULLY SNORKELED Vent lines Re-Routed Radiator Relocated 29.5 Laws on type 7's EPI Clutch Kit HMF Pipe Dyno Jet Kit Gorilla Axles 25" of G/C and 4:10 Gears BUILT BY ODB CUSTOM ORANGE 500 CAT

kscowboy View Member Profile	May 18 2005, 09:35 PM Post #6
"ROCKS DON'T FEEL PAIN. BE A ROCK!!" Group: Members Posts: 570 Joined: 15-November 04 From: Freeman Missouri Member No.: 4283 Your ATV: 05 cat 500 man	wahla!! FINISHED PRODUCT Attached File(s) clutch_kit_006.jpg ( 40.9K ) Number of downloads: 40 -------------------- "THE ROCK" Team "GET-YOU-SOME" 05 Cat 500 manual FULLY SNORKELED Vent lines Re-Routed Radiator Relocated 29.5 Laws on type 7's EPI Clutch Kit HMF Pipe Dyno Jet Kit Gorilla Axles 25" of G/C and 4:10 Gears BUILT BY ODB CUSTOM ORANGE 500 CAT

kscowboy View Member Profile	May 18 2005, 09:40 PM Post #7
"ROCKS DON'T FEEL PAIN. BE A ROCK!!" Group: Members Posts: 570 Joined: 15-November 04 From: Freeman Missouri Member No.: 4283 Your ATV: 05 cat 500 man	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. Attached File(s) clutch_kit_007.jpg ( 39.11K ) Number of downloads: 190 -------------------- "THE ROCK" Team "GET-YOU-SOME" 05 Cat 500 manual FULLY SNORKELED Vent lines Re-Routed Radiator Relocated 29.5 Laws on type 7's EPI Clutch Kit HMF Pipe Dyno Jet Kit Gorilla Axles 25" of G/C and 4:10 Gears BUILT BY ODB CUSTOM ORANGE 500 CAT

Scott F View Member Profile	May 18 2005, 09:47 PM Post #8
Scott Group: Members Posts: 114 Joined: 20-March 05 From: Vassar, Michigan Member No.: 6532 My Location: Vassar, MI Your Age: 29 Your Sled: 07 Polaris IQ600 CFI 07-08 Mileage (Sled): 750 06-07 Mileage (Sled): 1300 Your ATV: 2005 650 V2 RED 2007 Mileage (ATV): 350 2006 Mileage (ATV): 200	Very good info for the guys with the 500's. -------------------- 2005 650 V2 "BOB" 27 ITP 589 MS ITP Type 5 Wheels Moose Power Module Dalton Blue Primary Dalton Plain/Purple Secondary BF750 Belt 2500 lb Warn Winch AC Front and Rear Bumpers Dual 55W Rear Work Lights Red Bull Balls Hanging from Rear Bumper 2007 Polaris IQ 600 HO CFI

SLP40 View Member Profile	May 18 2005, 09:56 PM Post #9
Advanced Member Group: Members Posts: 159 Joined: 10-April 05 From: Loudon, TN Member No.: 6742 My Location: Loudon. TN Your Sled: 2006 Ford F-250 6.0L PowerStroke Your ATV: 2005 Arctic Cat 500 Lime Green 4x4 2007 Mileage (ATV): 356 2006 Mileage (ATV): 783	im scared!!! -------------------- - John Cobb 2005 Arctic Cat 500 Manual Lime Green "The Beast" ITP C-Series Type 6 Wheels with 27" Mudlites 10" on the front and 12" on the rear! Warn 2.5ci Winch Gel Handle Bar Grips HMF Utility Series Pipe DynoJet Research Jet Kit Custom 2" Snorkle EPI Clutch Spring Kit 2008 Kawasaki KFX450R "Stock for now" LOL

GoFastCat View Member Profile	May 18 2005, 09:57 PM Post #10
§©ØŦŦ Group: Members Posts: 5611 Joined: 17-August 06 Member No.: 13428 My Location: New Brunswick, Canada Your Sled: 1999 ZRT 600 - Sold Your ATV: 2004 DVX 400 - Sold	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. -------------------- ----------------------------------------------------

kscowboy View Member Profile	May 18 2005, 10:05 PM Post #11
"ROCKS DON'T FEEL PAIN. BE A ROCK!!" Group: Members Posts: 570 Joined: 15-November 04 From: Freeman Missouri Member No.: 4283 Your ATV: 05 cat 500 man	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. -------------------- "THE ROCK" Team "GET-YOU-SOME" 05 Cat 500 manual FULLY SNORKELED Vent lines Re-Routed Radiator Relocated 29.5 Laws on type 7's EPI Clutch Kit HMF Pipe Dyno Jet Kit Gorilla Axles 25" of G/C and 4:10 Gears BUILT BY ODB CUSTOM ORANGE 500 CAT

LittleCat View Member Profile	May 18 2005, 11:17 PM Post #12
Instigator Group: Members Posts: 4325 Joined: 1-June 04 Member No.: 2972 Your Age: 44 Your Sled: '02 AC ZR800 Your ATV: '04 AC 400i 4x4 Manual	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.

Bucanoles View Member Profile	May 19 2005, 08:47 AM Post #13
N A S T Y Group: Team Arcticchat Posts: 506 Joined: 9-February 05 From: Tallahassee, Florida "Home of the Seminoles" Member No.: 5822 My Location: In The MUD Your Age: 42 Your Sled: 2005 Chevy 2500HD ECSB Duramax 4X4 Your ATV: 05 500 Manual, 09 MUDPRO	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? This post has been edited by Bucanoles: May 19 2005, 10:27 AM -------------------- MUDPRO NEED PIPE

kscowboy View Member Profile	May 19 2005, 04:30 PM Post #14
"ROCKS DON'T FEEL PAIN. BE A ROCK!!" Group: Members Posts: 570 Joined: 15-November 04 From: Freeman Missouri Member No.: 4283 Your ATV: 05 cat 500 man	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 -------------------- "THE ROCK" Team "GET-YOU-SOME" 05 Cat 500 manual FULLY SNORKELED Vent lines Re-Routed Radiator Relocated 29.5 Laws on type 7's EPI Clutch Kit HMF Pipe Dyno Jet Kit Gorilla Axles 25" of G/C and 4:10 Gears BUILT BY ODB CUSTOM ORANGE 500 CAT

ProComp View Member Profile	May 19 2005, 04:36 PM Post #15
Advanced Member Group: Members Posts: 492 Joined: 11-April 05 From: Up North Member No.: 6744 My Location: Up North Your Sled: 2004 F7 Your ATV: 650 H1	Nice write up! As soon as I get my pipe/jet mod installed and perfected, maybe I'll tackle this. -------------------- 04 F6eb, 09 CFR800, 08 Prowler - 2" lift, 30 zillas SOLD - 06 650 H1, 4.0s, 29.5 Outlaws on Rockstars, HL springs, fully snorkled, rad on rack, HMF, 150 DJ, 42 Pilot, DJ needle, 4th notch, ammo boxes SOLD - 05 500 Manual, 29.5 Outlaws on ITP 6's. EPI Clutch Kit, 2" Snorkle, HMF with bracket from JAKE, 160 main, 42 pilot. Web Cam. Black plastics. SOLD - 03 500 manual, 27" MudBugs/28 Mudzillas, rear seat, rear fender protector/foot pegs, AC front fender extensions, 2" snorkle, clutch kit, AC1 Pipe, 165 main, 45 pilot, UNI filter

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