2018 Polaris Rzr Xp 1000 Secondary Clutch

Let’s be honest. You didn’t buy a RZR XP 1000 to putt around the yard. You bought it for the thrill—the instant acceleration, the ability to conquer tough terrain, and that satisfying feeling of power on tap. But what happens when that “snap” feels more like a “slush”? When you hit the gas and get more noise than go? Chances are, the unsung hero of your drivetrain needs some attention.

You’ve probably heard mechanics and forum gurus talk about it, but you might not be 100% clear on its role. We’re talking about your 2018 Polaris RZR XP 1000 secondary clutch, a critical component that often gets overlooked until there’s a problem.

Don’t worry, you’ve come to the right place. At FatBoysOffroad, we live and breathe this stuff. We promise this guide will demystify your secondary clutch, giving you the confidence to inspect, maintain, and even upgrade it. We’ll cover everything from what it does and common failure points to a step-by-step inspection process and the real-world benefits of an aftermarket upgrade.

What is the Secondary Clutch and Why Does It Matter?

Think of your RZR’s CVT (Continuously Variable Transmission) system as a team. The primary clutch, bolted to the engine, is the quarterback. It decides when to engage based on RPM. The secondary clutch, connected to the transmission, is the wide receiver. Its job is to catch the power from the belt and deliver it to the wheels efficiently.

The secondary clutch, also known as the driven clutch, is responsible for two crucial functions:

Backshifting: When you let off the gas or start climbing a hill, the secondary clutch senses the increased load. It forces the belt to ride higher, effectively shifting into a “lower gear” to keep the engine in its powerband. Good backshifting is key to that responsive, snappy feel.
Belt Squeeze: It maintains the proper tension on the CVT belt. Too little squeeze, and your belt slips, creating heat and robbing you of power. Too much, and you lose efficiency.

Without a properly functioning secondary, your RZR’s performance will suffer dramatically. It’s the component that translates your engine’s raw power into usable torque at the wheels.

Common Problems with the 2018 Polaris RZR XP 1000 Secondary Clutch

The 2018 model year is fantastic, but its stock secondary clutch has a few well-known weak spots. Recognizing the symptoms early can save you from a ruined belt or a long walk back to the truck. This section is a crucial part of our 2018 polaris rzr xp 1000 secondary clutch guide.

Signs of a Failing Secondary Clutch

Keep an eye (and an ear) out for these tell-tale signs:

Belt Slipping: You hit the gas, the engine revs high, but you don’t accelerate as you should. You might also smell burning rubber.
Poor Backshifting: The machine feels sluggish coming out of corners or when you get back on the throttle after coasting.
Strange Noises: A distinct “clunk” when you let off the gas or get back on it is a classic symptom. You may also hear squealing or grinding.
Jerky Engagement: The RZR lurches or feels grabby at low speeds.
Loss of Top Speed: If the clutch sheaves are worn or the spring is weak, the clutch may not be shifting out completely.

What Causes These Problems?

The most common culprit in the stock 2018 secondary clutch is the use of square pucks instead of rollers. These pucks slide inside the clutch’s helix and are prone to developing flat spots. Once they wear, they can bind, jam, and eventually break, causing that infamous clunk and poor performance.

Other failure points include:

Worn or Flat-Spotted Rollers: If your clutch has rollers, they can still wear out over time.
Broken Spring: The large spring inside provides the tension for backshifting. If it breaks or weakens, performance plummets.
Cracked Helix: The helix is the ramped component that the pucks or rollers travel on. A crack here is a critical failure.
Worn Bushings: The clutch rides on a central bushing that can wear out, causing excessive wobble and vibration.

How to Inspect Your 2018 Polaris RZR XP 1000 Secondary Clutch: A Step-by-Step Guide

Ready to get your hands dirty? A visual inspection is straightforward and is one of the most important 2018 polaris rzr xp 1000 secondary clutch tips we can offer. Knowing how to do this can save you hundreds in shop labor.

Tools and Safety First

Before you start, gather your tools. Safety is non-negotiable. Always wear safety glasses and gloves.

Socket set (typically 8mm and 10mm for the cover)
Torque wrench
Polaris belt removal tool (the L-shaped tool from your toolkit)
Secondary clutch compression tool (highly recommended for disassembly)
Clean rags
Non-chlorinated brake cleaner or isopropyl alcohol

Step-by-Step Inspection Process

Safety and Access: Park your RZR on a level surface, put it in park, and make sure the engine is completely cool. Remove the passenger-side rear wheel for easier access if needed.
Remove the Clutch Cover: Use your socket to remove the bolts holding the black plastic CVT cover on. Keep track of which bolts go where, as they can be different lengths.
Remove the CVT Belt: Insert your belt removal tool into the threaded hole on the secondary clutch. Turn it clockwise to spread the sheaves apart, which will loosen the belt. Simply walk the belt off the clutches.
Inspect the Belt: With the belt off, check it for glazing (shiny spots), cracks, frayed cords, or missing cogs. If it looks worn, now is the time to replace it.
Remove the Secondary Clutch: Remove the single bolt holding the secondary clutch to the transmission input shaft. It should slide right off. If it’s stuck, do not pry on the sheaves. A little gentle wiggling should free it up.
Disassemble the Clutch: WARNING: The internal spring is under high pressure. Use a dedicated clutch compression tool to safely relieve the tension before removing the snap ring that holds the helix in place. Attempting this without the proper tool can cause serious injury.
The Critical Inspection: Once apart, check everything. Look for flat spots on the square pucks or rollers. Inspect the channels they ride in for excessive wear. Check the helix for any hairline cracks. Ensure the spring isn’t broken. Clean the sheave faces and check for deep grooves or pitting.
Reassembly: Reassemble in the reverse order. Use the compression tool to reinstall the helix and snap ring. When you put the clutch back on the shaft, use your torque wrench to tighten the bolt to the factory specification (typically around 40-45 ft-lbs, but always check your service manual). Reinstall the belt and cover.

The Benefits of Upgrading Your 2018 Polaris RZR XP 1000 Secondary Clutch

If your inspection reveals worn-out stock components, you have a choice: replace with OEM parts or upgrade. For the 2018 model, an upgrade offers significant benefits of 2018 polaris rzr xp 1000 secondary clutch performance and reliability.

Enhanced Performance and Reliability

The biggest reason to upgrade is to replace the problematic square pucks with a true roller-style secondary clutch. Aftermarket clutches from trusted brands like STM, Gilomen Innovations, or Hunterworks use a helix designed for smooth-gliding rollers. This completely eliminates the binding and clunking issues of the stock design.

The results are immediate:

Instant Backshifting: The machine feels incredibly responsive.
Better Belt Grip: Superior designs and materials reduce belt slip, lowering belt temperatures and extending its life.
Increased Durability: High-quality billet aluminum and hardened steel components are built to withstand serious abuse.

Tuning for Your Riding Style

An aftermarket secondary clutch unlocks a new level of tuning. The helix, which controls the shifting characteristics, comes in various angles. A steeper angle allows for a more aggressive, faster upshift, great for dune riding. A shallower, multi-angle helix provides smoother engagement and powerful backshifting, which is ideal for rock crawling or technical trails. This is one of the most effective 2018 polaris rzr xp 1000 secondary clutch best practices for serious riders.

Best Practices and a Care Guide for Longevity

Whether you stick with stock or go for an upgrade, proper maintenance is everything. Following a simple 2018 polaris rzr xp 1000 secondary clutch care guide will maximize the life of your components.

Routine Maintenance Tips

After every few rides, especially in dusty conditions, pop your clutch cover off. Use compressed air (from a safe distance) to blow out all the belt dust and debris. This dust is abrasive and can accelerate wear on all your clutch components.

Every oil change, give the clutch sheave faces a quick wipe-down with a rag and some isopropyl alcohol or non-chlorinated brake cleaner. This removes any belt residue and ensures a clean surface for maximum grip. Never spray cleaners directly into the clutch, as you can wash grease out of bearings.

Sustainable and Eco-Friendly Clutch Care

Thinking about a sustainable 2018 polaris rzr xp 1000 secondary clutch might sound odd, but it’s really about a mindset of longevity and responsible maintenance. A well-cared-for clutch lasts longer, meaning fewer worn-out parts end up in a landfill. Rebuilding a clutch with quality components is far more eco-friendly than throwing the whole assembly away.

When you use cleaners, choose non-chlorinated versions and dispose of the used rags properly at a local hazardous waste collection site. It’s a small step that makes a big difference in protecting the trails and environment we all love to ride in.

Frequently Asked Questions About the 2018 Polaris RZR XP 1000 Secondary Clutch

How often should I inspect my secondary clutch?

A quick visual inspection and cleaning with compressed air should be done every 25 hours or after any particularly dusty or wet ride. A full disassembly and inspection of internal parts is recommended every 100 hours or 1,000 miles, or immediately if you notice any performance issues.

Can I just replace the square pucks with rollers in my stock clutch?

Yes, several companies sell roller conversion kits for the stock secondary. This is a great budget-friendly option to fix the main weak point without buying a whole new clutch assembly. It’s a very popular and effective modification.

What’s the difference between a straight and a multi-angle helix?

A straight-angle helix (e.g., 40 degrees) provides a consistent shift characteristic. A multi-angle helix (e.g., 45-35 degrees) has a changing ramp. It can be tuned to provide an aggressive upshift for acceleration while also having a different angle for powerful and smooth backshifting.

Do I need a special tool to change my RZR’s secondary clutch?

To simply remove and replace the entire clutch assembly, you only need the Polaris belt tool and a socket/torque wrench. To take the clutch apart to inspect or replace internal parts like the helix or spring, a clutch compression tool is absolutely necessary for your safety.

Your 2018 Polaris RZR XP 1000 secondary clutch is the key to unlocking the full potential of your machine. Understanding how it works and how to care for it puts you in control of your ride’s performance and reliability. By following this guide, you’re not just fixing a part; you’re investing in more confident, trouble-free adventures.

Now you have the expert knowledge to keep your RZR’s power hitting the dirt where it belongs. Ride hard, ride smart, and we’ll see you on the trails!

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Thomas Corle

Founder & Automobile expert at FatBoysOffroad

Automobile expert and off-road enthusiast, sharing in-depth knowledge of vehicles, gear, and adventures. Helping readers make smart decisions and enjoy the thrill of off-roading safely and confidently.