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Aspiring Perfectionist
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Discussion Starter #1 (Edited)
A conversation in my build thread (link in signature) led to me to want to collect some data that may be of use in terms of gear reductions on these machines. I compiled this spreadsheet for anyone that may need the info, I'll put a link at the bottom of this post to download the actual excel file, and I'll include a screenshot in the post.

I can't say this will give you all the info you need to do a gear reduction, SSG's threads linked below have a better description for some models that include parts numbers and what fits what, but I wanted to put this together for info to anyone who may be interested. I'll try answer any questions I can for you, and I'm sure there's quite a few people that have info more specific to certain models, but hopefully this will help in some light at least!

I tried to include all XPT-S, XPT, XP1000, & RS-1 models initially (2 seat & 4 seat), and from what I found while gathering all the data, anyone with a 570,800,900, or 1000 trail has a trans that matches one of these exactly, it's just a matter of pulling up your specific schematic and comparing.

This list has all available gear ratios i could find looking through OEM parts diagrams, it's as accurate as they are. It doesn't tell you specifically what you'll need to do for gear reduction, but it puts all the info in one place and can calculate reductions and actual gear ratios (to an extent) and will let you compare models to see where you'll be in relation to where you start or to another model you may be curious about.

There are 3 drop down menus at the top left (Base Machine, Compare Model 1 & 2) that you can select a model from and it will autofill the gears into the calculation area.

I'm not the foremost authority on what parts are interchangeable with what, and I'm always open to more info and suggestions. I don't have a lot of time to spend on modifying the table, but there's a lot more that could be done too it if i find time, and i might look into that in the future. I will try and answer any questions to the best of my ability if anyone has any, and I'll post some links to other threads with conversation on gear reduction as well, hopefully we can gather all this in one place so we don't have to search to the depths of the forums anymore, so maybe it will be a little more efficient.

I'll try to update this lead post as much as possible if new information comes to light in this thread so we don't have to page through everything if the thread stretches out to countless pages.

Some notes that I have found about gear reduction: (From Initial Posting, 1/4/2019)

The ACE 325 gearset (25/48) is the mostly universal reduction, this is the kit that SuperATV and several other places sell as well, it will provide a reduction across all ranges (H,L,R)
Polaris Part Numbers for this set: (Cheaper to buy the OEM gears direct)
#3235450 48T Stage 2 Gear
#3235451 25T Reverse Gear Shaft

67/25 is the lowest low gear I've found anywhere. Changing these gears will only reduce Low range If you have a multiple piece input shaft, this gearset come from a Ranger 1000 as are these part numbers:
#3235232 67T Low Gear
#3236132 25T Low Gear

Many machines also come with this low gear set from the factory (Ex: Highlifter, Rock&Trail, 2017 XPT4... many others), some use a one piece input shaft so you must replace the whole shaft to get the 25T gear, I might try to find time to compile a list of these machines over time.

Other Low gear sets are:
61/31
64/29

Your % of reduction will always be relative to the machine you start with... in example, I have a 2018 XPT4... i have the 61/31 low gear and 27/46 Stage 2 and Reverse Gear... which is pretty much the highest low gear you can get... I installed the 67/25 Low gear AND the 48/25 Ace 325 set.. so i have 53.49% reduction in Low and 12.7% overall... from those numbers that seems like a crazy low reduction.... but in reality... putting the Ace 325 gearset in a 2017 XPT4 (comes from factory with the 67/25 Low range set)... gets you a 12.7% reduction across all gears.... and now both machines have the same gearing across all ranges (Some machines have a different High gear as well... but we'll leave that for another day)

Forum member @RZRCrawlin says he has a guy the can provide a 49/24 aftermarket gearset to replace the Reverse Shaft and Stage 2 gear which would provide a 19.84% reduction across all ranges, some minor case grinding is required, and these aren't cheap gears, but that option is (in theory) out there now

Optimum Offroad sells some straight cut gears for several models, I'll note these are noisy and expensive, but they are an option as well. I believe these replace the idler shaft & stage 3 gear, so could be added to any reduction prior to that (not confirmed) (If anyone has any tooth counts or info on which gears these replace, please let me know and I'll add it to this info) Optimum Offroad

(You can make the blow photos bigger by right clicking and opening link in new tab or whatever your browser likes to call it)

Screenshot of my spreadsheet:


My gear labels for reference:


RZR_Joe's Diagram Label combined with my Labeling:


Links:
@RZR_Joe Thread:
Ultimate Crawler Transmission

@SSGPohlman Threads:
XP1K GEAR REDUCTIONS W PNs
XPT 2 GEAR REDUCTIONS WITH PN'S
RS1 GEAR REDUCTION W PNs
2015 900s 47% reduction writeup

My Build Thread:
My 2018 XPT4 "Bailey" and her Past, Present, And Future

Youtube Videos:

Roger Davis' Videos:

The 451 Removal and Disassembly Videos:

Solitude Customs 570/900 Video:



Drobbox Link To Download My Spreadsheet:
Gear Change Master Sheet
(Three dots in the top right of that screen will let you download the excel file)

Hopefully this can help someone figure this somewhat brain cramping topic out for their application! (or it'll make it harder... i hope not tho!)
 

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Aspiring Perfectionist
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Discussion Starter #3
If anyone tears into a trans and can get a gear count for 6A,6B,and 7A... (or just knows) please let me know so I can add them to the sheet... those tooth counts aren't listed on parts diagrams and would allow me to calculate the actual final drive ratios out of the case (for curiosity's sake if nothing else)
 

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Wow, perfect timing for me. Just tore into my 1st transmission and doing a rebuild . I was thinking it would be great if I could figure all this out. The good news is I don’t have to, you did. Thanks for putting this together.
 

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Discussion Starter #8
6a is 15, 6b is 53 and 7a is 11. This is on a ranger but those gears should he the same.


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Thank you, I believe that to be true on the machines with a 13T snorkel gear (7B).... but I'm pretty sure they're different on the models with a 19T
 

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Aspiring Perfectionist
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Discussion Starter #9
Wow, perfect timing for me. Just tore into my 1st transmission and doing a rebuild . I was thinking it would be great if I could figure all this out. The good news is I don’t have to, you did. Thanks for putting this together.
Glad to help! If you don't mind, while you're in there, let me know what you find for 6A,6B, & 7A (if you get into it that far)
 

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If anyone tears into a trans and can get a gear count for 6A,6B,and 7A... (or just knows) please let me know so I can add them to the sheet... those tooth counts aren't listed on parts diagrams and would allow me to calculate the actual final drive ratios out of the case (for curiosity's sake if nothing else)
I just got done with my transmission in a 18' XPT4. The main output gear or 6B has 61 teeth, and 6A had 16 teeth. I originally had found some pics online and showed a little different teeth count and could not get the final gear ratios to match up with with the factory showed. Now with the 61/16 it works. I think the other counts I found were out of a XP1K.

Let me know if you get your spreadsheet updated. I will be curious if you are able to get the correct outputs with those numbers.
 

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Aspiring Perfectionist
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2,101 Posts
Discussion Starter #11
If anyone tears into a trans and can get a gear count for 6A,6B,and 7A... (or just knows) please let me know so I can add them to the sheet... those tooth counts aren't listed on parts diagrams and would allow me to calculate the actual final drive ratios out of the case (for curiosity's sake if nothing else)
I just got done with my transmission in a 18' XPT4. The main output gear or 6B has 61 teeth, and 6A had 16 teeth. I originally had found some pics online and showed a little different teeth count and could not get the final gear ratios to match up with with the factory showed. Now with the 61/16 it works. I think the other counts I found were out of a XP1K.

Let me know if you get your spreadsheet updated. I will be curious if you are able to get the correct outputs with those numbers.


Thank you! I’ll try and do some updating this afternoon


Give it a second.... it had to go to space and back first ( Sent from the lifeline that is my iPhone7 )
 

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I just ordered my reduction from rzrworks for my 17 xp1k. It is 47/26/12%. I can make some counts when I tear into it. Thanks for all the great info.


Sent from my iPad using RZRForums.net
 

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Aspiring Perfectionist
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Discussion Starter #13
I just ordered my reduction from rzrworks for my 17 xp1k. It is 47/26/12%. I can make some counts when I tear into it. Thanks for all the great info.


Sent from my iPad using RZRForums.net


Sounds good, glad to help!


Give it a second.... it had to go to space and back first ( Sent from the lifeline that is my iPhone7 )
 

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I did find a few pics of the XP1K gears and it looked like the count for 6A and 6B were different. They looked like possibly a 60 and 17 tooth counts. I know they were different part numbers for the 1000 than what was being run in the Turbo trans.
 

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Discussion Starter #15
I did find a few pics of the XP1K gears and it looked like the count for 6A and 6B were different. They looked like possibly a 60 and 17 tooth counts. I know they were different part numbers for the 1000 than what was being run in the Turbo trans.
53/15 i believe are 6A and 6B on models with a 13T (7B) gear... that's what the ranger 1000 actually shows in the diagram, and what liftedspd2010 mentioned earlier, i don't think there's much variance in those gearsets either between a ranger and rzr... but i couldn't confirm it... the 1K and turbo are indeed different tho. I'm gonna play with the chart in a bit and see what comes out, I'll keep 60/17 in the notes as a possibility, thanks for the info
 

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Ill verify the 18' RS1 here within the next few weeks as Im doing a low gearset swap. unless DBRs1 beats me to it since he's doing an ace 325 swap.
 

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How much do the front diff gear ratios vary between models?

I just tore apart my front diff(#1333790), pinion has 11 teeth and ring gear has 35.

Curious if the XPTs, HL’s, T&R’s are different.
 

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Yes the XPT has a different ratio than the HL & RT. If I remember correctly the HL & RT is about 19% lower. Need to verify exact numbers
 

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Discussion Starter #20
How much do the front diff gear ratios vary between models?

I just tore apart my front diff(#1333790), pinion has 11 teeth and ring gear has 35.

Curious if the XPTs, HL’s, T&R’s are different.
Thanks for that info! 2017 XP4 1000 correct?

I'm still working on collecting all the front diff and output gear data to put into the sheet, it's a little harder to come by, but yeah there are variances, depends on how the output of the rear gear case is configured. I don't have my current spreadsheet with me, but i think so far i have found 3 different ratios for the front diff (purely based on gear ratio, part interchangeability isn't something I've looked into much as of yet)

The final drive ratio is slightly different between the front and rear wheels, that's one of the hings that makes the AWD function, so whatever output is from the rear case, the front diff has to change accordingly. (Output AFTER the gear selection in the rear case that is.... changing the gearing before 6A/6B above has not effect)
 
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