DURACLUTCHINSTALLATION15-500DCG1-RZR800RANGER800-MSRANGER700

SVI,LLCREV7PART#:15-500MODEL:DCG1-RZR800RANGER800-MSRANGER700 DESCRIPTION:RZR800ALLMODELS,RANGER800MIDSIZE,RANGER700ALLMODELSEXCEPTMY09RANGER7004X4 KITCONTENTS:110-071PRIMARYCLUTCH 2 25-164SHOULDERWASHER,SUPERSEDES90-019 3 10-055SECONDARYCLUTCH 4 3211162BELT 5 30-093 TOOL-BELTINSTALL 6 97-008 DECALS-CLUTCHHOUSINGANDDASH3211162 7 OWNERSMANUALSUPPLEMENT8 WEIGHTCHART9 DURACLUTCHWARRANTY 10 INSTALLATIONINSTRUCTIONS15-500(THESEINSTRUCTIONS)NOTEREGARDINGTORQUESTOPONMY05RANGERXP,MY06RANGERXP4X4700,MY07RANGER4X4700EFI,MY08RANGER700ALLOPTIONS,andMY09RANGER6X6700EFI:Thesemodelshaveanoriginalequipment(factoryinstalled)torquestop.Theengineandtransmissionaremountedindependentofeachother.Theengineisrubbermountedforvibrationisolation.Whentorqueistransmittedthroughthebelttherubbermountsflexandtheengineispulledtowardthesecondaryclutchonthetransmissiontendingtoloosenthebelt.Thepurposeofthetorquestopistolimittheenginepullbackwhenaccelerating(orenginebraking).Thetorquestopmaintainsbelttensionandkeepsthebeltfromslipping.TheRZR800andtheRANGER800MIDSIZEdonothaveafactoryinstalledtorquestopnorisatorquestopsuppliedwiththeDURACLUTCHkit.TheRZR800engineandtransmissionaremountedtogether.TheRANGER800MIDSIZEisnotdesignedtocarryorpullloadsofthefullsizeRANGERandatorquestopisnotrequired.PROCEEDURETOSETTHEORIGINALEQUIPMENTTORQUESTOPThetorquestopisanadjustablerubberpadonthemotormount(PN3021522shownonthepartscatalogdiagramENGINEMOUNTING).Insomecasesthetorquestopisonabracketbetweentheengineandtransmission.Beforeadjustingthetorquestopcheckthemotormounts(4places)toinsurenonearebroken(separated)orvehicleperformancewillbeadverselyaffected.Thebestwaytodothisistouseaprybartomovetheengineawayfromthemount.Ifthemountisbroken,itwillseparatewhenyoumovetheengineawayfromthemount.Toadjustthetorquestoptightentherubberpadagainstenginesothepadjusttouchestheengine.Backthepadoff½turn.Holdtherubberpadfromturningandlockthenut.Note:Ifthepadistightagainsttheenginewhenidlingorinsteadystaterunning,undesirableenginevibrationwillbefelt.Whentheengineisacceleratingorinenginebrakingmodeitshouldpullbackintotherubberpadtokeepthebelttightsoitwon’tslip.

DURACLUTCHINSTALLATION1. RemovetheSecondaryclutch.2. InstallDURACLUTCHSecondary.IfthereareanywashersbehindtheSecondary,removeone

washer.Tightenboltto17ft-lbf.3. RemovePrimaryclutchbolt.RemovethePrimaryclutchwithapuller(SVI25-147).Greasingtheend

ofthepullerslightlywillaidinremoval.Donotgetgreaseonanyclutchcomponents.4. Cleantheenginetaperedshaftandprimaryclutchborewithalcoholordegreaser.Donotlubricate.5. SlipthebeltintothePrimaryandovertheSecondary.6. InstallDURACLUTCHPrimarywithshoulderwasherasshown.DONOTUSEtheO.E.flatwasher.It

mayinterferewiththeprimarycover.Tightenboltto60ft-lbf.

7. InstalltheBeltasfollows,ifthePrimaryandSecondaryarealreadyinstalled.PlaceBeltinthe

PrimaryandopentheSecondarysheaveswiththeBeltInstallationToolprovided(seephoto).RollbeltintotheSecondarysheaves.

DURACLUTCHPRIMARYDrive

O.E.PlasticSleeve

ShoulderWasherSVIPN25-164,supersedes90-019SuppliedwithDURACLUTCHKit

DONOTUSEO.E.FlatWasher

O.E.Bolt

O.E.LockWasher

O.E.=OriginalEquipment

8. Setbelttension.PlacetransmissioninPARK!APPLYFOOTBRAKETOINSUREVEHICLEREMAINSSTATIONARY.ApplyslightthrottletoturnSecondary.

9. Installouterclutchhousing.Insuresealisgoodorreplace.TheDURACLUTCHprimaryisslightlylargerthantheoriginalequipmentprimary.Toinsuretheprimarydoesnotrubagainstthecoverpushupandbackonthehousingwhilelightlysnuggingthebottomscrews.Thentightenthetoprearscrewfollowedbytheothertopscrews.Thentightenallremainingscrewsincludingthebottomscrewsevenly.Afterstartingtheengineifyouheartheprimaryrubbing,pushonthecoverwhiletheengineisrunningindifferentdirectionstoseewhichwaywilleliminatetherubbing.Stoptheengineandloosenthehousingscrewsandretightenusingtheabovesequencewhilepushingonthecoverinthedirectionthateliminatedtherubbing.Ifthisdoesnoteliminatetherubbingtryinstallinganewgasketandgothroughthebolttighteningsequenceagain.Ifyoucannoteliminatetherubbingthecoverisheatwarpedandyoumayhavetoinstallanewcoverandperhapsanewbackplate.Youmayalsotryusingaheatguntoremoveheatsaginthecover.

DECALS10. Applytwodecalsasshown–oneontheclutchhousingandoneonthedash.Cleansurfacewith

alcoholorsimilarsolvent.DecalapplicationisimportanttoalertservicetechniciansthatthestandardPolarisclutcheshavebeenreplaced.