ULTRASHIFT XP INSTALLATION / REMOVAL ULTRASHIFT XP INSTALLATION / REMOVAL

ULTRASHIFT XP INSTALLATION / REMOVAL

WE ARE NOT RESPONSIBLE FOR ANY DAMAGES. BE VERY CAREFUL TO NOT DAMAGE YOUR CLUTCH DURING THIS PROCESS.

WHEN REINSTALLING THE COVER SCREWS PLEASE USE BLUE LOCKTITE AND TORQUE TO 10 FT/LBS (120IN/LBS).

 

TOOLS NEEDED

  • 1/2" Drive Impact Gun
  • T60 TORX - 1/2" Drive Socket 

  • 11/16 12 point - 1/2" Drive Impact Socket
  • 1/2" Torque Wrench (140Ft/Lbs)
  • 5mm Allen Wrench
  • 6mm Allen Wrench
  • 5/16" socket 

  • Pro primary clutch puller 

  • 15mm socket 

  • ARP Fastener lube
  • UltraShift primary holding tool (or equivalent)
  • Long 3/8" or 1/4" drive extension

ESTIMATED INSTALL TIME 25 MINUTES

Your ULTRASHIFT is a balanced assembly when you receive it. All parts are individually balanced then final balance checked after full assembly. The inner sheave assy balancing is done with the balance screws on the back of the primary fixed sheave. DO NOT REMOVE THE BALANCE SCREWS FOR ANY REASON. Always mark the components so they can be reinstalled in the same orientation orientation PRIOR to any disassembly. Failure to correctly reassemble your UltraShift may result in imbalance and subsequent damage. KWI will not be responsible for any damage due to improper assembly.

Your ULTRASHIFT comes with a generic pre-Installed baseline calibration. You are responsible for verifying that the cam arms and clickers are configured properly for your application PRIOR to clutch installation and testing for proper RPM. Baseline calibrations as follows.

Polaris RZR PRO XP Clicker 2, 2 magnets in the middle, 0 magnets in the tip 

Installation Steps:

1. Remove Belt Cover:

  • Use a 5/16" socket to remove the screws securing the belt box cover.  Lift the cover off and set it aside 

2. Remove CVT Belt:

  • Use a Clutch Belt Removal Tool to safely remove the CVT belt from the pulleys. 

 

3. Unbolt the Primary Clutch:

  • Use a T60 TORX - 1/2" Drive Socket to remove the primary clutch bolt. This bolt won’t be reused.
4. Detach Primary Clutch:
  • Remove the six 3/8” head bolts holding the primary clutch cover in place. This has only a small amount of spring tension and can be removed easily by hand this allows access the 2 piece center shaft. Twist and pop out.
  • Grease the primary clutch puller end and thread into the clutch bolt hole and tighten using an impact driver (or breaker bar with a pry bar through the clutch to hold it) until clutch is removed.
5. Remove Primary Clutch:
  • Take the primary clutch out of its position and keep it aside.

Critical Steps: Failure to follow these may result in damage.

6. Clean Crankshaft Bolt Hole:

  • Use the supplied wire brush and brake cleaner to remove any debris, oil, or rust from the hole. You can use the OEM clutch bolt to chase the threads if needed. Make sure the threads are clean and the ARP stud can thread in by hand easily.
 

7. Clean Crankshaft and Clutch Taper:

  • Wipe down the crankshaft and the taper on your new ULTRASHIFT clutch with brake cleaner or acetone to remove all residues.

8. Prepare ARP Stud:

  • Clean all threads with brake cleaner. Lightly apply the supplied ARP lubricant ONLY to the stud threads labeled GREASE at the Allen key end, as well as to the nut and washer. DO not apply any grease to the crankshaft threads! Screw the washer and nut onto the greased end of the stud until the end of the nut is flush with the end of the stud.

9. Install New Primary Clutch:

  • Place the ULTRASHIFT clutch onto the crankshaft taper then using a 3/16 Allen Wrench, screw in the ARP stud until the nut and washer contact the clutch center shaft. 

10. Torque Down:

  • Hold the ULTRASHIFT from turning with the ULTRASHIFT clutch Voorhees holding tool or equivalent.  Use a 1/2” Torque Wrench set to 140 ft/lbs to tighten the nut. (Make sure you re-check torque on the nut after the first 5 minutes of riding!!!)

Final Steps:

 

11. Adjust Belt Shimming:

  • Verify belt is centered in primary clutch and add or remove the Polaris shims under secondary clutch bolt washer as necessary for proper belt centering.

12. Re-Install Cover:

  • Put the belt box cover back on with oem screws..

13. Test Drive:

  • Drive the vehicle and check and adjust for proper full-throttle RPM according to your tuning chart below. (Make sure you re-check torque on the nut after the first 5 minutes of riding!!!)

UltraShift Primary Clutch Removal Steps:

1. Remove clutch from crankshaft:

 Failure to follow these steps may result in damage.

  • Remove Primary clutch bolt.
  • Critical Step-  Lubricate clutch puller threads and tip with Anti-Seize!!!

  • Thread Clutch puller in BY HAND until it stops.
  • Hold clutch from turning with Vorhees Vice.
  • Tighten clutch puller until clutch pops off crankshaft.