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duraclutch installation 15-500 dcg1-rzr800 ranger800 … · 2017-12-01 · 15-500 dcg1-rzr800...

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  • DURACLUTCH INSTALLATION 15-500 DCG1-RZR800 RANGER800 … · 2017-12-01 · 15-500 dcg1-rzr800 ranger800-ms ranger700 svi, llc rev7 part #: 15-500 model: dcg1-rzr800 ranger800-ms ranger700
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DURACLUTCH INSTALLATION 15-500 DCG1-RZR800 RANGER800-MS RANGER700 SVI, LLC REV7 PART #: 15-500 MODEL: DCG1-RZR800 RANGER800-MS RANGER700 DESCRIPTION: RZR 800 ALL MODELS, RANGER 800 MIDSIZE, RANGER 700 ALL MODELS EXCEPT MY09 RANGER 700 4X4 KIT CONTENTS: 1 10-071 PRIMARY CLUTCH 2 25-164 SHOULDER WASHER, SUPERSEDES 90-019 3 10-055 SECONDARY CLUTCH 4 3211162 BELT 5 30-093 TOOL-BELT INSTALL 6 97-008 DECALS - CLUTCH HOUSING AND DASH 3211162 7 OWNERS MANUAL SUPPLEMENT 8 WEIGHT CHART 9 DURACLUTCH WARRANTY 10 INSTALLATION INSTRUCTIONS 15-500 (THESE INSTRUCTIONS) NOTE REGARDING TORQUE STOP ON MY05 RANGER XP, MY06 RANGER XP 4X4 700, MY07 RANGER 4X4 700EFI, MY08 RANGER 700 ALL OPTIONS, and MY09 RANGER 6X6 700EFI: These models have an original equipment (factory installed) torque stop. The engine and transmission are mounted independent of each other. The engine is rubber mounted for vibration isolation. When torque is transmitted through the belt the rubber mounts flex and the engine is pulled toward the secondary clutch on the transmission tending to loosen the belt. The purpose of the torque stop is to limit the engine pullback when accelerating (or engine braking). The torque stop maintains belt tension and keeps the belt from slipping. The RZR 800 and the RANGER 800 MIDSIZE do not have a factory installed torque stop nor is a torque stop supplied with the DURACLUTCH kit. The RZR800 engine and transmission are mounted together. The RANGER 800 MIDSIZE is not designed to carry or pull loads of the full size RANGER and a torque stop is not required. PROCEEDURE TO SET THE ORIGINAL EQUIPMENT TORQUE STOP The torque stop is an adjustable rubber pad on the motor mount (PN 3021522 shown on the parts catalog diagram ENGINE MOUNTING). In some cases the torque stop is on a bracket between the engine and transmission. Before adjusting the torque stop check the motor mounts (4 places) to insure none are broken (separated) or vehicle performance will be adversely affected. The best way to do this is to use a pry bar to move the engine away from the mount. If the mount is broken, it will separate when you move the engine away from the mount. To adjust the torque stop tighten the rubber pad against engine so the pad just touches the engine. Back the pad off ½ turn. Hold the rubber pad from turning and lock the nut. Note: If the pad is tight against the engine when idling or in steady state running, undesirable engine vibration will be felt. When the engine is accelerating or in engine braking mode it should pull back into the rubber pad to keep the belt tight so it won’t slip.

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Page 1: DURACLUTCH INSTALLATION 15-500 DCG1-RZR800 RANGER800 … · 2017-12-01 · 15-500 dcg1-rzr800 ranger800-ms ranger700 svi, llc rev7 part #: 15-500 model: dcg1-rzr800 ranger800-ms ranger700

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.

Page 2: DURACLUTCH INSTALLATION 15-500 DCG1-RZR800 RANGER800 … · 2017-12-01 · 15-500 dcg1-rzr800 ranger800-ms ranger700 svi, llc rev7 part #: 15-500 model: dcg1-rzr800 ranger800-ms ranger700

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

Page 3: DURACLUTCH INSTALLATION 15-500 DCG1-RZR800 RANGER800 … · 2017-12-01 · 15-500 dcg1-rzr800 ranger800-ms ranger700 svi, llc rev7 part #: 15-500 model: dcg1-rzr800 ranger800-ms ranger700

8. Setbelttension.PlacetransmissioninPARK!APPLYFOOTBRAKETOINSUREVEHICLEREMAINSSTATIONARY.ApplyslightthrottletoturnSecondary.

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

DECALS10. Applytwodecalsasshown–oneontheclutchhousingandoneonthedash.Cleansurfacewith

alcoholorsimilarsolvent.DecalapplicationisimportanttoalertservicetechniciansthatthestandardPolarisclutcheshavebeenreplaced.


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