| An increasingly popular modification RZR owners are | | | | 5. Remove outer clutch cover screws and remove |
| doing is removing the plastic spacer that is on the | | | | clutch cover. |
| crank shaft in the drive clutch assembly. This can | | | | 6. Remove drive clutch assembly by removing the |
| increase your to RZR's top speed by as much as 10 | | | | clutch 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 constant | | | | clutch assembly on the left) To remove the clutch |
| velocity transmission (PVT) that consists of 3 major | | | | retaining bolt you will need to secure the drive clutch |
| assemblies, the drive clutch, the driven clutch, and | | | | assembly, aka the spider cage to keep it from |
| the drive belt. The drive clutch and the driven clutch | | | | spinning. 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 sensing | | | | is pressed onto the crank shaft and can be fairly |
| centrifugal force that cause shift weights to push | | | | easy to knock loose by tapping on it with a rubber |
| against rollers that push the movable sheave closer | | | | hammer. (This is where the factory service manual |
| to the other sheave to pinch the drive belt. The | | | | would tell you to use a drive clutch puller, which you |
| closer the two sheaves are pushed together the | | | | can 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 to | | | | to a work bench where you can install a spring |
| come completely together where the belt would | | | | compression 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 top | | | | plate on. Once bolts are removed you can then |
| speed anywhere from 5-10 mph. Some will say this is | | | | loosen 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 the | | | | Before removing the cover plate use a sharpie to |
| spacer and was added on later as an easy way to | | | | mark where it is aligned with the drive clutch |
| limit the RZR's top speed for liability reasons. We | | | | assembly. They need to be bolted back together the |
| have heard some arguments that removal of this | | | | same way because it is the way they were balanced |
| spacer will decrease the life of your drive belts, but | | | | from the factory. |
| we have yet to have any issues. A proper break in | | | | 8. After the cover plate has been removed you can |
| period at lower speeds for the first 100 miles on a | | | | slide the main clutch spring off and then remove the |
| new RZR or after a new belt is installed is highly | | | | plastic 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 simple | | | | clutch spring back on then with the clutch spring tool |
| process that requires a clutch compression tool that | | | | compress the assembly back together until you can |
| can be purchased through your local Polaris dealer | | | | get 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 gain | | | | the 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 the | | | | the 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 holds | | | | collar centers in the clutch shaft as you tighten. This |
| the clutch outlet duct to the clutch cover and slide it | | | | bolt needs to be torqued to 40 foot pounds. |
| off. | | | | |