Are you hitting your rev limiter after you clutch kit install?
Hitting the rev limiter after a clutch kit install on a Polaris RZR is not uncommon. The most vehicle it happens too is the four seat 1000 RZR, with the 1000 RZR being the second most common then other RZR's are way down the list on the occurance.
Clutch kits as a general rule increase engine RPM during shift phase, this is the very issue with the stock clutching you get lower engine rpm during shift phase especially with someone who changes tires but is that way in a bone stock vehicle. This means the clutch is shifting the belt out too fast and putting it in a lug losing peformance and making you go through more belts. A clutch kit puts rpm up there were we want it for better performance.
I use this example almost everyday. Say you have a four seater RZR 1000 and you ride in the dunes, you want shift speed up near 8500-8600 rpm, this does not leave you but 100-200 rpm to play with before you on the limiter. So if you have what I call a clutching mistake like say a flat spotted secondary roller etc that make RPM go up 200 RPM then you will hit the limiter. With stock clutching which may be say 600-800 rpm away from limiter during shift phase and you have the same 200 rpm clutching mistake it does not hit limiter because you are so far away from it. Does that mean stock clutching is better? No performance is off and belt use is higher.
Reason #1 in a four seater:
The clutch kit set ups are for four normal size people in a four seater so when you have four people in there the load is greater and you need lighter weights etc to get rpm up. If you only have two people in there, the load is less and the rpm is higher so the set ups may need to be adjusted with a different rivet, more set screws or a change in helix angle. You might need to call me on this but think more screws or heavier tip rivet. Also, if you ride four people in it most of the time, you really need to set it up with four people in it.
Reasons for both vehicles 1000 and 1000 four seat:
As a general rule the set ups in the kit are spot on with the normal add or take away a set screw in the weight, this is covered in the pre-installation article
Tire size, if you are using say a Skat Trak sand tire and maybe smaller than stock, the kit does not account for that, that is out of the normal, can it be changed for that? Sure but the set ups are not for a extremely light tire like that. I hear only 17lbs where the norm is mid 30's. You may need to call me on something like this with your kit and we can adjust away from the set ups for it.
The most common issue with hitting the limiter after a clutch kit install is a physical issue with one or both clutches. People call and say I don't have anything weird about my vehicle but I am hitting the limiter now. The set ups are not off that much. The most common reason is the primary nut has backed off causing the primary to limit travel, the second is a flat spotted secondary roller.
Again as mentioned earlier, you may not know you have a issue with the stock clutching because the shift phase rpm is so far away from the limiter that the clutch issue does not show up but it is there. Have had several people argue with me. " My vehicle only has 80 miles on it" Guess what? twice with less than 80 miles on them the spider nut backed off. Very common!!!
So to make it simple, if you are hitting the limiter either you have only two people in your four seater, you have a spider nut backing off, a secondary roller getting flat etc.
If you want to know what parts I am talking about or what to look for in the primary, watch our video