How to troubleshoot 3 of the Polaris RZR and Ranger Secondary Clutches

www.hunterwork...
This video explains what to look for when troubleshooting a Polaris Ranger or RZR non-turbo clutch. Three different secondary clutches are covered in this video.

[@jasonmelgoza4215]

Thank you very much informative. I am new to SXS but ex Mechanic so understand what you are talking about.

[@ICU-th7qj]

I just put a new primary and secondary on mine. The oem had 3500 miles on it with your rollers. I have been looking over them to find anything bad and can only really find very little wear on primary where the belt rides and some where it slides on the outside if that makes sense. My belt did have small cracks in it. I was also getting belt slap going down hill. I havent got to test it down a hill yet with the new clutch. I did also align everything with your tool and went to the float mod on the new clutch.

[@Hunterworks]

Is there a question in there somewhere? How can I help you? It read like you were describing the old clutch not the new.

[@ICU-th7qj]

@@Hunterworks sorta not really haha. Pretty much I put a new clutch on my RZR and was looking at the OEM one I took off just to see what could have been wrong and I'm not really seeing anything bad or wore. It had 3300 miles on it. I obviously had a issue because I was getting belt slap and definitely notice now with the new clutch that I wasn't getting at max rpms with the OEM. The only wear I can find is the rollers was getting cut from the secondary and the primary had some wear where the belt rode and where it slid in and out at the weights I geuss they are called. Also had belt slap going down hill. I geuss my question could be what could my problem have been?

[@Hunterworks]

@@ICU-th7qj THat I can't say, if not obvious then just over all wear

[@ICU-th7qj]

I did use your alignment tool and got it spot on. New clutch tool away that damn clunk noise and has a lot faster response now. Haven't got to see about the belt slap yet.

[@Hunterworks]

@@ICU-th7qj it won't be there either

[@bradhill5822]

Great series of videos!

[@Hunterworks]

Thanks

[@levieastman6252]

I got the primary and secondary clutch works great but now I hear a weird noise like I didn't get the secondary tight correctly i have the small kid seat in the middle and a 2012 rzr 800 s so it's a pain to even look 😅😢😢😢

[@enzoi9569]

Hi, I have a 15’ RZR 1000 XP, won’t go over 30-35 mph, ready to sell at this point, no engine codes, shops can’t figure it out, getting fuel and strong spark. Some are suggesting clutch issues, what should I be looking at? Primary and secondary are rebuilt with Gilomen plus a Gilomen performance tune. Any help is appreciated, thanks!

[@Hunterworks]

Does it hit the rev limiter at that speed or just go to a rpm and not go further?

[@darrrenbetker4266]

so if on my 17 xp1000which has 3000 miles and a brand new primary, what exactly is my problem with an extreme jerky start condition? new belt?

[@Hunterworks]

better to email me [e-mail] but what brand of clutch and belt is it?

[@RonDoiron-pz3ee]

2005 Polaris Ranger. Turned out the front motor mount was sheared off, the motor would twist a bit under torque, causing the primary to rub against the inner cover. I looked at a lot of secondary, could not find one similar to the one on this 500. It has a plate on the outside that appears to be a damper?

[@Hunterworks]

Well that would do it!!!

[@markmaas1133]

I have the pos clutch and plan on upgrading to yours in a month or so. Can I weld the spring up to the retainer plate to stop the noise. I think the noise comes from harmonic vibration of that cup being a separate piece from the plate that is bolted to the clutch.

[@Hunterworks]

You could try it but be careful about balance and that is some thin metal

[@daltoncornelson9656]

I have the pos secondary it came a part when I removed the belt is there a certain way to put it back together I put a new belt on that my dad ordered and it whistles So I was wondering if I put it on wrong

[@Hunterworks]

Did you remove the center bolt to remove the belt?

[@air-ace9729]

I have the pos secondary clutch bolt was super tight on the shaft but the clutch disc just spun out on the transmission drive shaft what is your thoughts why would it do that other than it's aluminum on steel

[@Hunterworks]

Not sure what you mean, send me a pic to [e-mail]

[@codybret.10]

Could you interchange the piece of crap clutch for the spring clutch on the same shaft?

[@Hunterworks]

What are you asking? What is the vehicle in question?

[@thorn3686]

for 2016 and up RZR 900 and 1000 non-turbo, skip to 10:20. these RZR's have a very crappy secondary with a not-strong enough spring. Not enough spring pressure and you lose clamping force at higher speeds and smoke belts.... pretty common problem

[@Hunterworks]

I do this everyday and sell a ton of belts, never hear about one slipping at higher speeds

[@thorn3686]

@@Hunterworks if you have a failing clutch, it can't help but slip, then destruct the belt..doesn't matter what the quality of the belt when it goes to slipping. Heats beyond limits and blows to pieces

[@Hunterworks]

@@thorn3686 you said weak spring, of course if you have a failing clutch

[@Hunterworks]

@@thorn3686 That is not what you said, you said they have a weak spring and causing it, failing is a obvious issue.

[@troyzincke7631]

2017 Polaris General Deluxe with EBS. Primary clutch is new from Gilman. I have the secondary clutch that is shown last in this video and it clunks when you first step on the gas in forward and reverse I can duplicate the sound just by spining it by hand backward and forward. Assuming this is normal for this type of EBS clutch correct? I have fully removed inspected and clean everything looks to be in proper order. Thanks for the thoughts

[@Hunterworks]

It is normal, just the roller switching sides in the helix

[@troyzincke7631]

@@Hunterworks Thank you for the timely response!

[@Hunterworks]

@@troyzincke7631 Welcome

[@jonathanclark4839]

I have a question about my 2008 Polaris RZR 800 Secondary clutch, the issue I'm having is it will not engage until about 3300-3500 RPMs with a load on it. But if I either put it in park and hit gas, or jack the rear tires off the ground and hit gas it engages like it should. What am I missing

[@Hunterworks]

All I can tell you is, your primary clutch is the problem, get a puller and inspect it and see what you see

[@codybret.10]

Would it be possible to replace the "piece of crap" clutch but just replace the side with the helix built in? Do they sell that part alone anywhere?

[@Hunterworks]

No it’s the whole clutch and nothing else would fit it

[@markmoczynski]

When I took the secondary clutch off there was two washers I couldn’t figure out where they Go and put them where I thought they were and I got a clunking noise now not good

[@Hunterworks]

what vehicle?

[@zomrob69]

I have a 19 ranger crew xp 1000 ... and it looks like it has the POS secondary. I just put a new belt on, did the break in period and today going 40 down the highway in high gear it shredded. Looks like a rats nest. When we got it home and buddy and I were looking at it, we put old belt back on, and it still moves. Is there a way that secondary clutch can get play in it? when it spins it looks like center bolt has a very slight egg rotation (if that makes sense) to it. I now hear a very faint metal sound ... dont think its the tranny but after watching these video series, I am thinking it may be the secondary ...

[@Hunterworks]

You do not have the POS on a XP 1000 Ranger and I would just have to see it, sounds like tranny shaft bent so far, so lets hope not email me [e-mail]

[@eddiereichel9354]

I have an 09 sportsman xp 550. Belt seems ro be in middle. Belt seems really tight. Like it sticks up out of secondary whole wau around. Is rhat normal?

[@Hunterworks]

Yes

[@eddiereichel9354]

@Hunterworks I replaced the primary and shifting got worse. When I installed it it seemed belt was in middle. You said if that's the case it's the primary

[@Hunterworks]

@@eddiereichel9354 What brand of primary clutch did you buy? The bearing is the issue new or not if nothing else is touching the belt unless this is one of those that has no bearing in it and uses slack on the belt to allow idling in gear.

[@eddiereichel9354]

@@Hunterworks Caltric was the brand. Ebay.

[@eddiereichel9354]

@@Hunterworks There is a bearing which turns 1 way in the center of the primary.

[@joshbrown3091]

Just received my new secondary team tied clutch like the first in your video for my 17 900xp. I have the snap ring on the shaft but cannot seem to get the clutch to line up flush with the shaft. What is it I’m doin wrong? Thanks.

[@Hunterworks]

It’s not supposed to

[@mountainmangarage7572]

i have a 2019 ranger 500 the secondary is spinning at idle and causes it to die. Do i need a new secondary or can it be repaired?

[@Hunterworks]

Your issue is in the primary and we recommend the duraclutch system we sell for this model, just be done with it. I run it myself

[@mountainmangarage7572]

@@Hunterworks thanks allot

[@Hunterworks]

@@mountainmangarage7572 if you want to troubleshoot it, we have a how to troubleshoot a primary video too

[@mountainmangarage7572]

@Hunterworks Inc. I will look that up thank you

[@BigAlWillis]

Working on a secondary for a friend. It took three of us to remove the belt. Clutch didn't expand at all. Seems rusted. Shouldn't the belt come off easily?

[@Hunterworks]

What vehicle

[@BigAlWillis]

@@Hunterworks ranger 800 Polaris

[@BigAlWillis]

@@Hunterworks it shredded the belt so I went to help look at it. After installing the new belt the vehicle didn't move. I noticed the secondary wasn't expanding so we wrestled the belt back off. It seemed to be tight as possible.

[@Hunterworks]

@@BigAlWillis Sounds like you need to take the secondary apart and see what you see that would be causing it not to open. Keep in mind though if the primary is not working right, it will not close therefore the secondary will not open

[@Hunterworks]

@@BigAlWillis secondary stock closed with a new belt on it, it will move at least to around 10 mph where the secondary starts to open, sounding more like a primary issue to me

[@jasonwrenn2493]

I have the POS on my 2016 Ranger Crew 900. Just busted my rollers and oh shit clips, and replace them. Guess I will be calling you for a new secondary.

[@Hunterworks]

I won't lie calling can be tough but the better secondary is available on our Ranger page on our site, choose the ranger helix, spring and our HD rollers

[@josephbearlewis]

All yostuff is awsome

[@Hunterworks]

Thank you

[@bigman21024]

On a 14 ranger 900 what would cause the secould half to be stuck on the shaft

[@Hunterworks]

Probably corrosion

[@Aloha_Crypto]

I have a 2014 diesel that has the shifter moving between gears ⚙(N-H) but will not move with gas...was driving yesterday just fine🤦‍♂️🤷‍♂️

[@RonDoiron-pz3ee]

It’s a tapered fit on the primary. You need the right tool, available on line. The secondary is on a spline. Line up is done with shims on the tranny shaft.

[@robertpage2927]

If you have pos secondary I do what is replacement 2015 570 putting a new engine in don't want trouble

[@Hunterworks]

What? Think you have some typos, that does not make sense to me.

[@BradleyBeeksAdventures]

My secondary clutch exploded today and we just got the RZR, went to change the belt on the trail then realized it the clutch that broke, the spring and everything is hanging out lol.

[@Hunterworks]

That is not good, we have new ones and advice if needed

[@BradleyBeeksAdventures]

@@Hunterworks could you send me a link ? It’s a 2013 RZR 800

[@Hunterworks]

@@BradleyBeeksAdventures Sorry, only have the duraclutch for that no individual clutches for a 800

[@BradleyBeeksAdventures]

@@Hunterworks okay thanks.

[@donniejordan2431]

What wrong when you are on high gear and it's moving real slow

[@Hunterworks]

I would need more information than that. Shoot me an email [e-mail] and give me a little more details because right now it sounds like you need to give it more gas lol

[@iveneverdonethisbefore8390]

Great.....I have the POS clutch lol

[@Hunterworks]

well when it goes, we have a better one

[@reconn3cted276]

A lot of rambling...try and get to the point of the video quicker 😊

[@Hunterworks]

speaking of rambling^^^^^^^^ Besides I was not in a hurry, watch faster maybe!! HEHE