INSTALLATION GUIDE POLARIS RZR X302 - X302T CLUTCH KIT

PART NUMBER(s): RZRX300

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

TOOLS NEEDED

• 8mm Socket
• 3/8" 1/4 Drive Socket
• 1/4" Drive Ratchet
• 3/8" Drive Ratchet
• 15mm 3/8 drive Socket
• 1/8" Allen wrench
• Torque Wrench
• Polaris Clutch Belt removal tool
• Blue Locktite

ESTIMATED INSTALL TIME 45 MINUTES

NOTE: No component marking is required before disassembly. This drive pulley features factory index marks as references if needed.

Primary clutch disassembly and reassembly

1. Remove belt box cover. (8mm socket)
2. Remove CVT belt. (Polaris Clutch Belt Removal Tool)
3. No need to remove the primary clutch from the crankshaft Remove the 6 bolts securing the cover and replace factory weights with KWI weights and magnets as outlined in the appropriate chart below. Install the correct primary clutch spring as outlined in the appropriate tuning chart below and install the primary clutch cover- torque bolts to 12 Ft lbs. (It is the installers responsibility to verify the torque specs and KWI will not be held accountable for any damage) 

Secondary clutch disassembly and reassembly

1. Remove secondary clutch bolt. (15mm socket)
2. Remove the secondary from the splined shaft by removing the bolt and c-clip (if applicable) and sliding the clutch off the shaft.
3. Separate secondary clutch halves by sliding them apart and put a threaded rod thru inner half with helix and clamp carefully with 2 washers and 2 nuts. There is substantial spring pressure so ensure you use the correct tools.
4. Remove 3 bolts attaching helix to moveable sheave. Relieve spring tension by unscrewing threaded rod nuts. Note position and orientation of components.
5. Remove secondary spring and install KWI secondary spring. Reassemble secondary components in order removed and carefully compress using threaded rod or KWI tool kit.
6. Reinstall 3 screws thru sheave and into helix using blue Locktite. Torque to 35 ft lbs.
7. When the secondary is assembled install it back on the shaft and bolt in place. Torque the secondary bolt to 35-40 ft-lbs. (It is the installers responsibility to verify the torque specs and KWI will not be held accountable for any damage ) 

MAGNET RPM ADJUSTMENT

This requires the cam arms be removed from the clutch. The weight of the added magnets affects RPM. The more magnets that are installed the lower the RPMS will be. 1 thick magnet from each weights will change Full Throttle RPM approx 100 RPM

1. Remove the cam arms from the clutch. (SEE "Primary clutch disassembly and reassembly" ABOVE)
2. There are 3 holes in the arms to place magnets- you can place magnets in holes as required. Magnets in the hole closest to the cam arm pin will affect RPM's from 0-20 MPH. Magnets in the center hole will affect RPM's from 20-50 MPH. Magnets in the hole farthest to the cam arm pin will affect RPM's at 50+ MPH.
3. Magnets MUST be distributed so that the clutch is balanced. Make sure arms have identical magnets installed. Do not overfill magnet slots!
4. For sand dunes or tires larger than 33" remove 2 total thick magnets from the recommended low altitude trail settings then test full throttle RPM at 55mph and adjust if necessary.
5. For high riding elevations above 5000' remove 4 total thick magnets from the recommended low altitude trail settings then test full throttle RPM at 55mph and adjust as necessary.
6. Reinstall the cam arms and tighten to spec.