DURACLUTCH MY18-20 2018-2020 Ranger XP 1000 Clutch Installation Guide

: October 27, 2023
: DURACLUTCH

Table of Contents

MY18-20 2018-2020 Ranger XP 1000 Clutch
KIT CONTENTS:
DURACLUTCH INSTALLATION
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

DURACLUTCH INSTALLATION
15-534 DC-RANGER1000-Z MY18-20
SVI, LLC REV1 25FEBL2022

MY18-20 2018-2020 Ranger XP 1000 Clutch

KIT PART #: 15-534
MODEL: DC-RANGER1000-Z MY18-20
DESCRIPTION: MY18-20 RANGER XP1000 MY19-20 RANGER CREW XP1000. This model has the Polaris P90X Clutch.
Does not fit MY18 RANGER CREW XP1000. This model has the Polaris P190X CLUTCH.

KIT CONTENTS:

10-174 ASM-DCPRIM WT10-240 SPR50-001
25-146 BUSHING-CLUTCH WASHER
75-047 SCREW-CLUTCH
99-024 TOOL-12MM BIT SOCKET 3/8 DRIVE
99-028 TOOL-T60 BIT SOCKET 3/8” DRIVE
10-220 ASM-DC SECONDARY 9.5 PREM ROLL
35-057 BELT 3211196
99-023 LOCTITE 243 0.5ML CAPSULE 1330255
30-091 TOOL-BELT INSTALL 2877408
97-020 DECAL-DC CLUTCH HOUSING DASH
38-028 DONGLE-DURACLUTCH 1
95-079 CABLE TIE 14IN W/CLIP QTY 2
99-025 CABLE TIE 8IN QTY 4
OWNERS MANUAL SUPPLEMENT
WEIGHT CHART
DURACLUTCH WARRANTY
98-057 INSTALLATION INSTRUCTIONS 15-534 (THESE INSTRUCTIONS)

DURACLUTCH INSTALLATION

Remove airbox to plenum hose clamps and move hose out of the way.
Remove the clutch housing cover. Recommended tool: 8mm socket with flex drive extension.
Remove Primary clutch bolt. Remove the Polaris primary outer movable sheave assembly. Pull off by hand holding the central shaft in place with your thumb. Move around the clutch, with a pulling and rocking motion.
Pull the Polaris primary fixed sheave from the engine crankshaft using PN 99-012 puller. Greasing the end of the puller slightly will aid in removal. Do not get grease on any clutch components.
Clean the engine tapered shaft and DURACLUTCH Primary clutch bore with alcohol or degreaser. Do not lubricate.
Remove the Secondary clutch.
Install DURACLUTCH Secondary using stock bolt and washer. Stock shim washers are not used. (see pic below) Place blue Loctite on stock secondary bolt threads and tighten bolt to 45 ft-lbs.
Slip the belt into the Secondary so you can read the part number on the belt and using Belt Install Tool open up secondary so belt will seat down into clutch. Sometimes a screwdriver is needed to seat lower into clutch.
Slide primary clutch into belt, then install on post.
Install DURACLUTCH Primary hardware provided as shown. VERY IMPORTANT -Torque bolt to 60 fluff. Over tightening will not allow clutch to operate properly.
Once primary is torqued, with transmission in PARK, spin secondary clutch back & forth a few times to allow belt back to top of secondary.
How to install a Belt if the Primary and Secondary are already installed. Place Belt in the Primary and open the Secondary sheaves with the Belt Installation Tool provided. Roll belt into the Secondary sheaves. Sometimes a screwdriver is needed to seat lower into clutch.
Install outer clutch housing. Ensure seal is good or replace.
Install airbox to plenum hose removed in step 1.
Dongle comes with 2 cable ties with clips installed. Install onto rear passenger side vehicle frame, push clips down so they bite down on frame.
Take two 8-inch cable ties and feed thru tab on top of dongle housing and around the frame and tighten.
Disconnect speed sensor on transmission. Connect end from dongle to transmission. Connect wire removed from transmission into other end of dongle. Make sure Dongle does not interfere with any moving components, such as suspension or shifting assembly. Use remaining cable ties to secure wires as necessary and clip excess tie ends.
Drive vehicle for 5 miles to break-in DURACLUTCH kit components.
NOTE: If the transmission shifts hard after break-in there are likely issues other than drag in the clutches. See your dealer or call DURACLUTCH service (218-967-8205).
DECALSApply two decals as shown – one on the clutch cover housing and one on the dash. Clean surface with alcohol or similar solvent. Decal application is important to alert service technicians that the standard Polaris clutches have been replaced.