An increasingly popular modification RZR owners are making is removing the plastic spacer found on the crankshaft in the transmission clutch assembly. This can increase your top speed to RZR by as much as 10 mph.

The RZR’s transmission is a pulley-based constant speed transmission (PVT) consisting of 3 main assemblies, the drive clutch, the drive clutch, and the drive belt. The drive clutch and drive clutch consist of two tapered-shaped pulley halves, called pulleys. The transmission works by sensing the centrifugal force that causes the shift weights to push against the rollers that push the movable pulley closer to the other pulley to pinch the drive belt. The more the two pulleys are pushed together, the more the belt is pushed.

Removing this spacer allows the two pulleys to fully come together where the belt would move to the larger diameter of the pulleys. We have found that this will increase your RZR’s top speed by 5-10 mph. Some will say this goes against the original transmission design, but we speculate that it was designed without the spacer and was added later as an easy way to limit the RZR’s top speed for liability reasons. We’ve heard some arguments that removing this spacer will reduce the life of your 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 limiting spacer is a simple process requiring 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 access the outer clutch cover.

3. Remove the rivets and fasteners holding the rear seat base and remove them from the vehicle.

4. Using a screwdriver, loosen the clamp that secures the clutch outlet duct to the clutch cover and slide it out.

5. Remove the outer clutch cover bolts and remove the clutch cover.

6. Remove the drive clutch assembly by removing the clutch retaining bolt that threads into the crankshaft. (Facing the rear of the vehicle, the transmission clutch is the clutch assembly on the left) To remove the clutch retaining bolt, you will need to secure the transmission clutch assembly, also known as the spider cage to prevent turn. A wooden hammer handle slipped into the spider cage works well for this. The clutch assembly is pressed onto the crankshaft and can be quite easy to release by hitting it with a rubber hammer. (This is where the factory service manual will instruct you to use a transmission clutch puller, which you can order through your local dealer, part # PA-48595)

7. Once the drive clutch assembly is removed, take it to a workbench where you can install a spring compression tool. Once attached, you can loosen the 6 3/8 “bolts holding the clutch cover plate. Once the bolts are removed, you can loosen the spring compression tool by unloading the clutch spring and then remove the cover plate Before removing the cover plate use a marker to mark where it is aligned with the transmission clutch assembly.

8. After removing the cover plate, you can slide the main clutch spring and then remove the plastic spacer that was inside.

9. With the plastic spacer now removed, slide the clutch spring back and then with the clutch spring tool, compress the assembly again until you can get the 3/8 “bolts to start. Tighten the rest of the bolts. tight trail at 20 foot-pounds.

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 out, making sure the plastic collar is centered on the clutch shaft as you tighten. This bolt should be tightened to 40 foot-pounds.