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How to Install a Clutch Kit on Your 2016 Polaris RZR Turbo

2016 Polaris RZR Turbo

Most people only dream of glory — you’re making those dreams come true. By getting a Dynojet clutch kit for your Polaris RZR Turbo, you’ll tap into a rush of performance greater than the stock model you purchased.

Before you get started, Dynojet recommends that clutch kit installation be performed by a qualified technician, as there are special tools you need.

If you’re riding at high altitude, you’ll need to make some adjustments before installing your Dynojet clutch kit. 

  • 3000 ft. above sea level: subtract 1 magnet (from each arm starting from toe side) 
  • 6000 ft. above sea level: subtract 2 magnets (from each arm starting from toe side) 
  • 7500 ft. above sea level: subtract 3 magnets (from each arm starting from toe side) 
  • 9000 ft. above sea level: subtract 4 magnets (from each arm starting from toe side) 

Please note that our settings represent a general baseline, and your situation may require a different setup. Some factors that may affect clutch setup: tire brand & size, state of clutch wear, drive belt condition, engine power output, and environmental conditions. Please thoroughly inspect your clutch for wear and tear before installing a Dynojet clutch kit.

Additionally, how you plan to ride your Polaris will affect which springs you install.

Tools You’ll Need

Unless you have all of these tools, we recommend entrusting installation to an authorized Polaris technician.

  • Clutch Puller
  • 21mm Socket
  • 15mm Socket
  • Snap Ring Pliers
  • T27 Torx
  • 3/8” Socket
  • 1/8” Allen Key

How To Install

You can remove the left-hand side rear shock to give you better access to the clutch housing and parts, but it’s not necessary for installation.

Step 1

Start by removing all 8mm head bolts for the plastic clutch housing, then remove the clutch housing. 

Step 2

Mark the direction of the drive belt and then remove it. 

Step 3

Using the Polaris clutch puller, remove the primary clutch. It is recommended to grease the threads of the clutch puller before using. 

Step 4

Remove the 6 bolts for the primary spring cover. Be sure to remove the bolts evenly, as there is a significant amount of spring pressure.

Step 5

Remove the clutch arms, using the 3/8” socket and the 1/8” Allen key. 

Step 6

Install the Dynojet clutch arms with the proper amount of weight. Refer to the table earlier in the post. 

Step 7

Install the Dynojet primary spring and reinstall the spring cover. Tighten the 6mm bolts evenly to 9 ft-lb (12 Nm).

Step 8

Next, remove the secondary clutch. Use a 15mm socket to remove the retaining bolt. Remove the snap ring and slide the secondary clutch off the input shaft. Before taking the clutch apart, be sure to mark the stationary sheave, moveable sheave, helix and cover with a reference mark. 

Step 9

Remove the 3 Torx head bolts. This cover is under extreme spring pressure, so be sure to use a clutch compression tool.

Step 10

Replace the stock spring with the Dynojet spring. Reassemble the secondary clutch paying attention to the alignment marks and reinstall on the input shaft. Make sure you reinstall the thrust bearing, thrust washer and snap ring. Torque the retaining bolt to 43 ft-lb (58 Nm). 

Step 11

Reinstall the primary clutch on the output shaft. Torque the retaining bolt to 96 ft-lb (130 Nm), then re-install the drive belt.

Tuning Notes

For optimized performance, your RPM when checked at 50 mph should be 8400 rpm. This should be checked on a surface that offers good traction and tested with a normal load in the vehicle. 

Adjustments to the overall weight of each clutch arm may be necessary to achieve this RPM target. Also, know that optimized RPM will be much different if you’re riding in the sand or mud, versus a test run on the dyno. It is not uncommon to see a loss of 300 to 400 rpm if you’re using paddle tires. Our settings are based on using a Power Vision 3 tune in the ECM.

Once you’ve installed, you’re ready to take your Polaris outside and Push The Limit!