I pirated this from hunterworks, here you go!!

First let me say I don't recommend this at all because you can damage your primary sheave shaft if you are not careful but here goes.

Take the cover off the CVT and look into the primary sheave and find the plastic spacer. Take a chisel and cut the plastic spacer with it and a hammer then rotate it over and either pull it off or cut it again.

After riding some more my RZR runs 65mph now.

 

cool thanks i'll see how i like it with the mods i am putting on

 

UTV let me know if that mod causes any problems within the next few months as I want to do it to mine but can't afford to tear anything up right now......

 

PDM (pdmaz.com) in Phoenix, Arizona offers this service for $189.95 I think (NOT 100% sure, just rumor I heard), he does it a little more complex and more careful from what I read above I'd assume as he is one of the most reputable clutch guys in Arizona !! Give him a call

 

I've heard the chisel method works well, takes only a few minutes (all of 'em spent removing/replacing the cover), but if you're too aggressive you can nick the shaft. I don't know what type plastic the spacer is made from but I'd try melting thru it with a hot blade before resorting to whacking it. No reason to pay someone to do such a simple mod.

 

warranty... if something goes wrong you have someone to turn to. and i think he is actually replacing the spacer with a new one.. but if you want to do it yourself, more power to you, just no recourse if you blow your clutch up, or do any other damages to your car.

 

I was going to use a hot blade or a flat soldering iron I have to make sure I don't damage the shaft but I don't want to screw anything up. I just got my manual so I'm ready to do all this stuff now.

 

I didn't risk it. I took mine down to my dealer and he and i took it apart and removed the spacer. It takes a special tool to take the clutch apart. This mod works great for top speed increase, won't help the bottomend just the topend. This is a simple way to pick up a quick 8-10 mph. Warranty still good.

 

Dobber,
How much did the dealer charge you?

 

Guys guys guys,

Please do not use a chisel, one wrong move and you could do alot of damage to that clutch shaft. After you remove the cover, then remove the 7 bolts around the clutch( this is NOT under any presure from the spring) then remove that outer part of the clutch, reach in , grab the spacer and remove it, now retorque the 7 bolts, done. No need to remove the clutch and no fancy tool needed. You will gain 5 mph.

Martin

 

He is right, I posted that you would need a special tool, but to do this mod its not needed I had a brain fart there for a min. My point is take the time to take it apart and do it the right way. You will need to torque the bolts back though. This is very simple and only takes about 1/2 hour to 45 min.

to answer the other question my dealer didn't charge me he's a good friend and we do stuff like this all the time.

 

RZR Crap will be offering a couple of different clutch packages in the next few weeks here. We are going to Glamis to test different springs and setups to find the best duner kit for the RZR!

 

Let us know when you have a good dune setup. I will be heading to glamis most of the winter.

 

Hello, I have had my RZR for about a month and removed the spacer for a short period but put it back in after about 50 miles because the belt exploded. I think that removing the spacer caused this because if you remve the spacer put the RZR in neutral and rev it up before putting the cover back you will see that the belt rides most of the way out of the clutch sheaves. It will run up to around 68 MPH if you look at your speedometer at the 70 MPH mark there is a red mark and it will run rite up to the red mark. JUST MY 2 Cents. I have 600 miles on mine now with no other problems but the spacer was removed at around 110 miles and the belt exploded at 168 miles.

 

Just to let everyone know i talked to dirty dawg and he told me not to remove the spacer. the reason you dont want to do this is because if you look at the shaft it has a step up that helps keep the spacer in place and if you remove the spacer the clutch will ride out to far and catch on this slim step up. its hard to see with the eye but if you feel for it you can tell. however it looks like you can make the spacer a hair smaller. might get 1 to 2 mph. after he told me this i took mine apart and sure enough there is a step up. he said it wont happen unless it catch's and it will be to late when it catch's. sorry to pi$$ on your 5 to 10 mph but if you have this step up on your shaft dont do it.

 

This has obviously been a big topic of debate lately...

Now what you say may be true, but there's hundreds or even thousands of people with the spacer removed that haven't had a single problem with a ton of miles and hours on them...

There's also some that HAVE had a belt snap... but that's also happened to people WITH the spacer, so it's hard to directly relate it.

Here's my thinking...

Worst case scenario? The belt breaks.

I have a spare that I carry and ride with (like everybody should) and it's a nice Goodyear belt that only cost me $50. If that means I can ride for the next few months... or heck even year before I manage to break the belt... that's only what, $50 for a NICE top end gain over all that time?

Worth the cost of a belt, even if it is the "rare" cause of failure from time to time. Easily the cheapest mod for MPH per dollar spent!

 

from what i can see if you take the spacer out the two primary pulley half's can ride the belt up until thay touch. dirty dawg said it would not be good if thay touch. he also said that some of the gen 1 dont have the step up. Looking at my set up the pulley half's will hit before the step up will touch. Im giving epi a call to see what thay have to say.

 

Right, but I'm just saying WORST case is, you throw a belt...

It's really not a big deal, for the top end you're gaining v.s the price of a belt...

 

i wrote up a little mini article on the procedure.
no special tools are needed above a torque wrench.. i wouldnt do the chisel trick, it's really easy to take the clutch cover off and put it back on. it took me about 20 minutes when i did mine almost a year ago..
i have exploded one belt and burned another one up, but neither were due to the clutch spacer..
Troubleshooting Wiki

 

I just got off the phone with dalton and he has not done anything with the clutch on a rzr but he said the sportsman 800 has a limiter in it and he takes it out. he also said that its ok if the clutch halfs touch. he said snomobiles do it all the time. also said if you run it for a long ways down the road you can blow the belt. that being said i think the best thing to do is open it up and find out how fast it is and than keep it 1mph below top speed. Make sure you check top speed on flat ground or a vary small incline. this way you will be safe at 1mph under top speed.

 

I've only been able to BARELY touch the top speed on most the trails I go on...

I don't ever just take it on asphalt roads or anything like that... so it's not an issue.

 

When i go to upper michigan we can run the county roads and there's alot of open area. Me and my friends are always drag racing or trying to through mud on each other. I looked into making the spacer thinner but there's only 1/6 of an inch to play with. I could take a 32nd of and see what happens. maybe.

 

I think what most people have agreed on but i don't know for sure is taking the spacer out and cutting it down to about 1/3 it's original size. This way you get the perfomance gains but it is just about at the point that it does not allow the belt to slip all the way out of the clutch and fry it. Dont know for sure but just my .02 from what i have heard and witnessed

 

from what i can see if you take the spring out and leave the spacer in. than put the cover back on. you can slide the primary clutch back and forth and if you slide it all the way in there's only a 1/16 of a inch gap between the pulley half's. and if you take the spacer out the two half will touch if you slide the primary all the way in. so this tells me that the only thing you can do to the spacer is take 1/32 off. if you take 1/16 or more the spacer wont be doing anything and at that point i would take it out and hope for the best.

 

I think you're exactly right... shaving it down probably doesn't even do ANYTHING, and it's like not having one at all...

 

i have put in the clutch mod with the belt and springs. didnt know about the spacer part to remove. is this safe???

 

Libird, whose clutch mod & belt did u use. I just finished putting EPI's in last night. As to you spacer question, BELIEVE it or NOT, my RZR did not have a spacer in it. So I'll try to do a post tonight and let u know if not having it is a problem. Got to redial in the Boondocker cause of the clutch mod's. Bart

 

LiBird, rather than repeating a post, check out my response in the
Secondary Clutch Spring post. It's an eye opener. Couldn't tell if I was hitting Rev Limiter by not have clutch spacer installed. I plan on testing some more if and when it quits raining.:rollfinger: Hope info in other post is helpful. Bart

 

blackbart ive herd of some gen 1 not having the spacer what was your top speed when you were bone stock. and is yours a gen 1. also did you see a step up on the primary shaft this is where the spacer rides. if you take your cover off again look vary close at the shaft and tell me if you have a step up you might have to feel for it. Its vary thin. if you follow the shaft to the motor end it starts there and comes out a 1/2 inch. I would like to know this because maybe the step up is whats causing the belts to have trouble. Im thinking of taking 1/32 of spacer just to be safe.

 

I am still wondering how the "S" can run without the spacer and the RZR cannot? We need an experinced clutch tunner to tell us the difference and why.