Polaris RZR Performance – Get Free 10 Mph
An increasingly popular modification that RZR owners are doing is removing the plastic spacer that is on the crankshaft in the drive clutch assembly. This can increase your RZR’s top speed by up to 10 mph.
The RZR’s transmission is a pulley-based constant velocity transmission (PVT) consisting of 3 main assemblies, the drive clutch, driven clutch, and drive belt. Both the drive clutch and the driven clutch consist of two conical-shaped pulley halves, called pulleys. The transmission works by sensing the centrifugal force which causes the shift weights to push against the rollers which push the movable pulley closer to the other pulley to pinch the drive belt. The closer the two pulleys are pushed, the more the belt is pushed.
Removing this spacer allows the two pulleys to fully meet where the belt would move toward the larger diameter of the pulleys. We found this will increase your RZR’s top speed by 5-10 mph. Some will say this goes against the original design of the transmission, but we speculate that it was designed without the spacer and added later as an easy way to limit the RZR’s top speed for liability purposes. We’ve heard some arguments that removing this spacer will reduce the life of the drive belts, but we haven’t had any issues yet. A proper break-in period at lower speeds is highly recommended for the first 100 miles on a new RZR or after installing a new belt to ensure longer life.
Removal of the plastic limiter spacer is a simple process that requires a clutch compression tool that can be purchased through your local Polaris dealer (part # 8700220).
1. Remove the driver and passenger seats.
2. Remove the panel behind the seats to gain access to the outer clutch cover.
3. Remove push rivets and fasteners securing rear seat base and remove from vehicle.
4. Using a screwdriver, loosen the clamp holding the clutch output passage to the clutch cover and slide it off.
5. Remove the outer clutch cover bolts and remove the clutch cover.
6. Remove the transmission clutch assembly by removing the clutch retaining bolt that threads into the crankshaft. (Looking towards the rear of the vehicle, the drive clutch is the clutch assembly on the left) To remove the clutch retaining bolt, you will need to secure the drive clutch assembly, also known as the spider cage to prevent let it turn A wooden hammer handle slipped into the spider’s cage works well for this. The clutch assembly is pressed against the crankshaft and can be loosened quite easily by hitting it with a rubber mallet. (This is where the factory service manual would instruct you to use a transmission clutch puller, which you can order through your local dealer, part number PA-48595)
7. Once the drive clutch assembly is removed, take it to a workbench where you can install a spring compression tool. Once it is tight you can loosen the 6 3/8″ bolts holding the clutch cover plate. Once you have removed the bolts you can loosen the spring compression tool unloading the clutch spring and then remove the cover plate. Before removing the cover use a felt pen to mark where it lines up with the drive clutch assembly. They should be bolted back on the same way because that is how they were balanced at the factory.
8. After removing the cover plate, you can slide the main clutch spring in and then remove the plastic spacer that was inside.
9. With the plastic spacer removed, refit the clutch spring, then using the clutch spring tool, compress the assembly again until you can begin to fit the 3/8″ bolts. Tighten them all the way. with a torque of 20 pound-feet.
10. Reinstall the pulley assembly by sliding it back onto the crankshaft, then reinstall the clutch retaining bolt that threads into the crankshaft. Make sure you have the lock washer, thick washer, and plastic collar the way they came off, making sure the plastic collar is centered on the clutch shaft as you tighten it. This bolt should be torqued to 40 foot-pounds.