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