How to Remove the Clutch on a Polaris RZR

Removing the clutch on a Polaris UTV may be the first step to a bigger project, such as installing a rebuilt clutch.

Thankfully, removing the clutch on a Polaris RZR only requires a handful of tools, including a clutch puller. Here are some other tools you’ll need, as well as the steps involved to remove the clutch on a Polaris RZR.

Tools Needed – Polaris RZR 900XP Clutch Removal

  • ½ inch, 3/8th ratchets
  • 10mm, 15mm, 21mm, 26mm sockets

Polaris RZR 900XP clutch removal

Removing the Clutch on a Polaris RZR

Step 1. Remove the clutch cover by loosening and removing the 10mm bolts that hold the perimeter of the cover in place. 

PRO TIP: Unless you remove the shock absorber, it’ll be a tight squeeze, but the cover will come out. 

Polaris RZR clutch removal

Step 2. Loosen and remove the bolt in the center that holds the driven (or secondary) clutch in place.

Polaris RZR driven clutch removal

Step 3. Repeat Step 2 for the drive (or primary) clutch. 

Polaris RZR primary clutch remoal

Step 4. Insert the clutch puller into the hole in the center of the drive clutch. Thread it on clockwise, then use your ratchet to get enough torque on it to break it free. 

Polaris UTV clutch removal

NOTE: Check with the manufacturer’s specifications to make sure you’re using the right clutch puller. It’ll take some force to pull out the primary clutch, and it’ll be loud when it breaks loose, so be ready for that.

EPI clutch puller tools

Step 5. Remove the clutch puller, and pull the primary clutch out of the machine.

Step 6. Remove the clutch belt.

Step 7. Remove the secondary clutch from the machine and you’re done. 

Polaris RZR side-by-side clutch removal

If the purpose of removing the clutch on your Polaris side-by-side was to replace it, watch the video below to learn how to install a clutch on a Polaris RZR 900XP.



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