2008 800 XP Clutch Kit Installation

Secondary

1. Remove Canister (4 Springs)
2. Loosen chain tensioner
3. Remove oil from chaincase
4. Remove chaincase cover
5. Remove top bolt
6. Pull tab gear and spacer behind gear
7. Go to clutch side
8. Behind the secondary there is a bolt with a retainer, remove the 13mm bolt
9. Install provided bolt into chaincase side of the jackshaft, lightly tap bolt until shaft pops out of the bearing holder
10. As soon as the shaft moves, remove bolt and remove shaft and secondary
11. Remove black belt adjuster
12. Install D&D tool
13. Tighten bolt on too until it separates sheaves to 1/16 in
14. Lightly heat four bolts on backside secondary

Primary

1. Remove 22 mm bolt from primary
2. Install primary clutch puller
3. Tighten until primary clutch comes off (may have to apply heat on inner sheave)
4. Remove Clutch Puller
5. Apply heat on outer primary where puller goes
6. Install 3 retainer clip holders
7. Remove 3 bolts by using proper tool
8. Remove spring
9. Install new spring
10. Install 3 bolts
11. Remove pins from arms
12. Install proper weight (23 grams)
13. Line both arrows on sheaves to arrow on cup
14. #T27 bit to remove 4 bolts
15. Remove bolt from tool and slide cam out
16. Remove white bushing
17. Install white bushing with new cam
18. Line arrows on each sheave to the arrows on the cam
19. Install bolt back into D&D tool
20. Tighten bolt until cam hits the sheaves
21. Install bolts with blue loctite