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Crank Puller

Polaris RZR Performance - Gain 10 mph for Freedom

A modification of the owners increasingly popular RZR is doing is to remove the separator plastic is on the crankshaft in the drive clutch assembly. This can increase your maximum speed RZR by as much as 10 miles per hour.

The RZR transmission is a pulley based constant velocity (PVT), which consists of 3 major assemblies, the drive clutch, clutch and belt. The clutch and clutch both consist of two halves in conical pulleys, called. The transmission works through the detection of the centrifugal force that the weights change due to push against rollers that push the movable pulley sheave near the other to pinch the drive belt. The closer the two sheaves are pushed further out and the belt is pressed.

The removal of this spacer allows the two beams come completely together where the tape would move to a larger diameter on the sheaves. We find that this will increase your speed anywhere from 5 to 10 mph RZR. Some say this goes against the original design of the transmission, but we speculate it was designed without the spacer and was added later as an easy way limit the maximum speed of the RZR for reasons of liability. We have heard some arguments that the removal of this separator will reduce the life of your drive belts, but have not yet had any problems. A break in the appropriate period at lower speeds for the first 100 miles in a new RZR or after a belt new install is highly recommended to ensure a longer belt life.

The removal of the plastic limiting spacer is a simple process that requires a clutch compression tool which can be purchased through your local Polaris dealer (part # 8700220)

1. Remove driver and passenger seats.

2. Remove the panel behind the seats to get to the outer clutch cover.

3. Remove the push rivets and fasteners holding base and remove the rear seat of vehicles.

4. Use a screwdriver to loosen the clamp that holds the outlet of the clutch on the clutch cover and slide out.

5. Remove outer clutch cover screws and remove clutch cover.

6. Remove drive clutch assembly by removing the retaining bolt clutch that screws into the crankshaft. (Facing the rear of the vehicle's clutch is the clutch assembly on the left) To remove the retaining pin clutch will have to set the clutch assembly, also known as spider cage to prevent the tour. A handle of a wooden hammer went in the spider cage works well for this. The clutch is pressed on the crankshaft and can be quite easy to play loose clicking on it with a rubber hammer. (Here is where the factory service manual will tell you to use a drive clutch puller, which can be ordered through your local dealer, part # PA-48 595)

7. Once the clutch assembly is removed take it to a workbench where you can install a tool spring compression. Once who took drastic measures can loosen the 6 3 / 8 "screws holding the clutch cover plate. Once the bolts are removed, then loosen compression tool download spring clutch spring and then remove the cover plate. Before removing the cover plate using a Sharpie to mark where aligned with the drive assembly of the clutch. They must be screwed back together in the same way because it is the way they were balanced from the factory.

8. After the cover plate is removed you can slide the mainspring clutch and then remove the plastic spacer that sat inside.

9. With the plastic spacer slide has picked up clutch spring back then with the clutch assembly tool to compress spring back together until you can get the 3 / 8 "bolts started. them the rest of the way Tighten torque 20 lb ft.

10. Reinstall the pulley assembly from sliding new crankshaft, then reinstall the clutch retaining bolt that threads into the crankshaft. Make sure you have the washer, thick washer and the plastic ring on the way out to make sure the plastic collar centers in the clutch shaft while tightening. The screw is be tightened to 40 foot-pounds.

About the Author

To learn more about Polaris RZR's visit http://www.polarisrzrheadquarters.com where you'll learn everything you need to know about Polaris RZR parts, accessories, and long travel suspensions.

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