Polaris RZR Performance - Gain 10 mph for Free

An increasingly popular modification RZR owners are5. Remove outer clutch cover screws and remove
doing is removing the plastic spacer that is on theclutch cover.
crank shaft in the drive clutch assembly. This can6. Remove drive clutch assembly by removing the
increase your to RZR's top speed by as much as 10clutch retaining bolt that threads into the crank shaft.
mph.(Facing the rear of the vehicle the drive clutch is the
The RZR's transmission is a pulley based constantclutch assembly on the left) To remove the clutch
velocity transmission (PVT) that consists of 3 majorretaining bolt you will need to secure the drive clutch
assemblies, the drive clutch, the driven clutch, andassembly, aka the spider cage to keep it from
the drive belt. The drive clutch and the driven clutchspinning. A wooden hammer handle slipped into the
both consist of two conical shaped pulley halves,spider cage works well for this. The clutch assembly
called sheaves. The transmission operates by sensingis pressed onto the crank shaft and can be fairly
centrifugal force that cause shift weights to pusheasy to knock loose by tapping on it with a rubber
against rollers that push the movable sheave closerhammer. (This is where the factory service manual
to the other sheave to pinch the drive belt. Thewould tell you to use a drive clutch puller, which you
closer the two sheaves are pushed together thecan order through your local dealer, part # PA-48595)
further out the belt is pushed.7. Once the drive clutch assembly is removed take it
Removal of this spacer allows the two sheaves toto a work bench where you can install a spring
come completely together where the belt wouldcompression tool. Once it is clamped down you can
move out to the largest diameter on the sheaves.loosen the 6 3/8" bolts that hold the clutch cover
We have found this will increase your RZR's topplate on. Once bolts are removed you can then
speed anywhere from 5-10 mph. Some will say this isloosen the spring compression tool unloading the
going against the original design of the transmission,clutch spring and then remove the cover plate.
but we speculate that it was designed without theBefore removing the cover plate use a sharpie to
spacer and was added on later as an easy way tomark where it is aligned with the drive clutch
limit the RZR's top speed for liability reasons. Weassembly. They need to be bolted back together the
have heard some arguments that removal of thissame way because it is the way they were balanced
spacer will decrease the life of your drive belts, butfrom the factory.
we have yet to have any issues. A proper break in8. After the cover plate has been removed you can
period at lower speeds for the first 100 miles on aslide the main clutch spring off and then remove the
new RZR or after a new belt is installed is highlyplastic spacer that sat inside it.
recommended to ensure a longer belt life.9. With the plastic spacer now removed slide the
Removal of the plastic limiting spacer is a simpleclutch spring back on then with the clutch spring tool
process that requires a clutch compression tool thatcompress the assembly back together until you can
can be purchased through your local Polaris dealerget the 3/8" bolts started. Tighten them the rest of
(part # 8700220)the way torqued to 20 ft pounds.
1. Remove driver and passenger seats.10. Reinstall sheave assembly by sliding it back onto
2. Remove panel that is behind the seats to gainthe crank shaft, then re install the clutch retaining bolt
access to the outer clutch cover.that threads into the crank shaft. Be sure you have
3. Remove the push rivets and fasteners holding thethe lock washer, thick washer and the plastic collar
rear seat base and remove from vehicle.on the way they came off making sure the plastic
4. With a screw driver loosen the clamp that holdscollar centers in the clutch shaft as you tighten. This
the clutch outlet duct to the clutch cover and slide itbolt needs to be torqued to 40 foot pounds.
off.