Hunterworks - Clutch Tool and Lock Plate

Clutch Spacing/Alignment Tool and Lock Plate

The article below is older but not changing it much, everything still applies to all the vehicles except we now have our own alignment tools for most all Polaris vehicles that work as good as the older one we used to carry from SDI. Our alignment tools, are just as accurate, easier to use and much less money.

The 1000XP and XP4 has had a good bit of issues with the clutch system and one of the biggest has not gotten talked about much until now by us because we didn't have you and answer to the problem but with the help of SDI we do now.

What is the problem? Shaft spacing and alignment issues. The RZR engine and transmission is connected to the frame at each end and bolted together in the middle. What happens is the engine/tranny start sagging in the middle over time and the shafts get closer together therefore the belt gets slack, rpm goes up, the belt slips and the belt starts hitting the top of the back cover at the top of cover near the exhaust duct plus it starts blowing belts.

I would like to say there are a couple other issues too, the shafts can be too far apart from factory causing a very tight belt, makes a noise and then there are times it was set wrong from factory and shafts too close together.

Then the biggest issue that has not been able to be addressed until this tool came out is "alignment" and we do not mean by traditional standards like one pulley is not inline with the other we mean on angle. Let me explain but using exaggerated angles

The engine and tranny are bolted together with six bolts and as mentioned they move over time but they don't always sag straight down. So the engine for an example could sag straight down but the tranny could sag on an angle like say more movement in the mounts on passenger side than drivers side and it sits at an angle. So picture the crank sitting straight and the tranny shaft at a 45 degree angle (exaggerated). So if you didn't have this tool and you simply had the tool that is a flat bar with a hole in each end that is spaced 10 1/2" apart you could set the spacing but not the alignment or angles. With that tool you can only get one of the issues straightened out. Actual alignment meaning one inline with other can't hardly be off because of the design of the engine/tranny mount but the angle at which that sit to each other can be off . Kinda hard to explain. Guess a good visual would be to take a birds eye view looking straight down at the shafts, the front one straight an the transmission shaft twisted a bit.

Using our alignment tools, allows you to make sure the engine and transmission shafts on that are spaced 10 1/2" on center apart and parallel to each other.

Once you have it all set correct then there is the optional locking plate. The locking plate locks the engine and tranny in this spot so it will not move in the future. As mentioned in the install video you may need to tap a couple holes already in the engine side and we offer those taps to do the job. That was a short and sweet explanation of the plate but in the end that is all it does, just lock it all in place.