Keep your firearm in best condition


Polaris RZR Performance - Gain 10 mph for Free

An increasingly popular modification RZR
owners are doing is removing the plastic5. Remove outer clutch cover screws and
spacer that is on the crank shaft in theremove  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 basedthe crank shaft. (Facing the rear of the
constant velocity transmission (PVT) thatvehicle the drive clutch is the clutch
consists of 3 major assemblies, the driveassembly on the left) To remove the clutch
clutch, the driven clutch, and the driveretaining bolt you will need to secure the
belt. The drive clutch and the driven clutchdrive clutch assembly, aka the spider cage to
both consist of two conical shaped pulleykeep it from spinning. A wooden hammer handle
halves, called sheaves. The transmissionslipped into the spider cage works well for
operates by sensing centrifugal force thatthis. The clutch assembly is pressed onto the
cause shift weights to push against rollerscrank shaft and can be fairly easy to knock
that push the movable sheave closer to theloose 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 togetherwould 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 belt7. Once the drive clutch assembly is removed
would move out to the largest diameter on thetake it to a work bench where you can install
sheaves. We have found this will increasea 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 thehold the clutch cover plate on. Once bolts
original design of the transmission, but weare removed you can then loosen the spring
speculate that it was designed without thecompression tool unloading the clutch spring
spacer and was added on later as an easy wayand then remove the cover plate. Before
to limit the RZR's top speed for liabilityremoving the cover plate use a sharpie to
reasons. We have heard some arguments thatmark where it is aligned with the drive
removal of this spacer will decrease the lifeclutch assembly. They need to be bolted back
of your drive belts, but we have yet to havetogether the same way because it is the way
any issues. A proper break in period at lowerthey  were  balanced  from  the  factory.
speeds for the first 100 miles on a new RZR
or after a new belt is installed is highly8. 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 clutch9. With the plastic spacer now removed slide
compression tool that can be purchasedthe 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 to10. 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 fastenersthe crank shaft. Be sure you have the lock
holding the rear seat base and remove fromwasher, 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 thatyou tighten. This bolt needs to be torqued to
holds the clutch outlet duct to the clutch40 foot pounds.
cover  and  slide  it  off.



1 A B C D 62 63 64 65 66 67 68 69 70 71 72 74 75 76 77 78 79 80 82 83 84 85 86 87 88 89 90 91 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110