Continuously Variable Transmissions (CVT) are won- derful things, as they help deliver engine power to the drivetrain and automatically vary final drive
ratios. CVTs have primary and secondary clutches and
variable-diameter sheaves connected by a belt. Basically,
as the primary clutch gains revs, it expands with centrifugal
force, which causes the belt to act on the secondary clutch
and force the sheaves apart. It’s like replacing a large rear
sprocket with continuously smaller ones through the rev
range for more top speed. The spring-loaded secondary
uses a combination of plastic rollers and sliders to facilitate
REBUILD A CVT SECONDARY
the expansion and contraction of the two sheaves, which, over
time, can gall the sheave faces. Also, dirt wears the plastic
sliders and can eventually damage the secondary housing,
causing the rollers to flat-spot. A sticking secondary blows
On our 2015–2017 Polaris RZR XP 1000s, the sliders
(#3514926) are 28 x 13.5mm and the rollers (#3514929)
are 9. 58 x 28. 83 x 13.97mm. Inspection of our 2015 XP1K
showed galling and roller wear, so we set out to rebuild and
upgrade the secondary. This procedure will also apply to those
installing a CVT clutch kit with a different secondary spring.
Polaris sliders and rollers are $25 to $30
apiece, so Hunterworks made a replacement kit with high-grade exotic plastic that
is impregnated with a substance that is five
times slicker than Teflon. The rollers have
tighter tolerances than the injection-molded
stock rollers, which are loose on the shaft.
12097 Kelly Lane
Collinsville, MS 39325
With your RZR clean and dry, place it on level ground and in park. With a
flexible-drive extension and 8mm socket, loosen the CVT-duct hose clamp.
With a 10mm socket, remove the duct-support bracket, and hook the duct in
front of the shock.
Remove the 8mm-head CVT cover bolts and place them in a container with
the 10mm duct bolt. Rotate the rear of the CVT cover up to clear the shock
and remove. We replaced the sliders on 2016+ and 2014–2015 RZR XPs.
Newer XPs have square sliders; 2014–2015s have rollers. Using the OEM
CVT spreader tool, force the secondary sheaves apart and rotate counterclockwise to remove belt.
Our impact driver wasn’t strong enough to break loose the 15mm bolt, so we
held the secondary with a long screwdriver against the radius rod and loosened
the retainer bolt with a pry bar.
They’re tested to 400 degrees with no
deformation and CNC-manufactured in the
Prices are $60 for the secondary roller
kit and $65 for the 2016–2017 secondary
roller conversion kit. Both have four high-lubricity rollers and pins, enough for two