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Offline NMKawierider

CLUTCH WORK - ZForce 800 Clutch R&R Plus Clocking Video!
« on: March 15, 2016, 06:09:47 PM »
As requested, here's one way to remove and replace your clutches on the ZForce. My mistake, I didn't get a video on doing the clocking and assembling  of the secondary so you will have to refer to the second video for that. Sorry.

Here's taking them off:


Here's clocking the secondary.  These two aren't mine...or me...lol:



And finally putting them back on or reinstalling them:

« Last Edit: July 01, 2020, 04:41:22 PM by NMKawierider »
2015 Z Force 800 (53") EPS -
Custom Air Intakes | Custom Exhaust Mod | SuperATV Harness | Custom Fenders | Custom Skid/Rock Sliders | 27" GBC Grim Reapers | Seizmik Mirrors |Конструктор (Rodin's) Doors | Dr Pulley Sliders | 1.5" Wheel Spacers | BENZ Silencer (as needed) | SATV Flip Windshield W\ Rear Shield | Dual Light Bars | Diamond Plate Storage | 9.7" GPS | Bandit Springs Rear & Gen-3 Shocks Front

My Videos On YouTube

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Offline Cosmosdan

Re: ZForce 800 Clutch R&R
« Reply #1 on: March 15, 2016, 10:16:56 PM »
This is very helpful. Thanks for sharing this
2013 Z6 Trail
Iron Baltic skid plates
UE Boom Speaker mount
RZR 800 Shocks
Mostly stock trail riding
25g. Rollers and A1

2016 Outlander max 570
Too new for mods yet

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Offline tdonnar

Re: ZForce 800 Clutch R&R
« Reply #2 on: March 16, 2016, 09:10:52 AM »
This is really good information. I was just getting ready to try a clutch adjustment. This will really help.
Thanks!!!!!

2014 ZForce 800 EX
« Last Edit: March 16, 2016, 09:13:33 AM by tdonnar »

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Offline Gphennig

Re: CLUTCH WORK - ZForce 800 Clutch R&R Plus Clocking Video!
« Reply #3 on: October 21, 2018, 11:16:38 PM »
How do you like the dr pulley sliders? I’ll likly try the clocking first, then sliders if clocking doesn’t give my unit the low end I need

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Offline NMKawierider

Re: CLUTCH WORK - ZForce 800 Clutch R&R Plus Clocking Video!
« Reply #4 on: October 22, 2018, 08:58:03 AM »
How do you like the dr pulley sliders? I’ll likly try the clocking first, then sliders if clocking doesn’t give my unit the low end I need
Great. I like them a lot. They work well and go a little more in both directions. Stick with the 24 gram though if you are below 5K feet. I went with the 22s because I ride from 5400 to about 12K and work fine but most of my riding is below 9K and sometimes kinda wish I has 23s or 24s .
2015 Z Force 800 (53") EPS -
Custom Air Intakes | Custom Exhaust Mod | SuperATV Harness | Custom Fenders | Custom Skid/Rock Sliders | 27" GBC Grim Reapers | Seizmik Mirrors |Конструктор (Rodin's) Doors | Dr Pulley Sliders | 1.5" Wheel Spacers | BENZ Silencer (as needed) | SATV Flip Windshield W\ Rear Shield | Dual Light Bars | Diamond Plate Storage | 9.7" GPS | Bandit Springs Rear & Gen-3 Shocks Front

My Videos On YouTube

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Offline Sockman

Re: CLUTCH WORK - ZForce 800 Clutch R&R Plus Clocking Video!
« Reply #5 on: February 24, 2019, 10:47:58 AM »
A thousand thanks for posting this.  Got this disassembled.  Had to make the "spanner" tool, and that worked like a champ.  Breaker bar with an extension and that one loosened right up.  My air impact wouldn't budge the drive pulley nut, so spent some money on a nice cordless one (1200ft/lbs) and that spun it right off.  Haven't got the clutch apart yet to reclock it, ran outa time.  Still need to figure out the other spanner tool so I can torque the drive pulley.  Not a bad job so far.  Once the tools are made, should be easy really.

I wonder if I can modify the one tool to do both jobs.
« Last Edit: February 24, 2019, 11:06:17 AM by Sockman »
2017 Zforce 800 EX
UNI filter, SuperATV high clearance a-arms, half windshield, nerf bars, Windjammer rear window, overhead storage, Bighorns, Bandit suspension Gen3 shocks, rear camera

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Offline NMKawierider

Re: CLUTCH WORK - ZForce 800 Clutch R&R Plus Clocking Video!
« Reply #6 on: February 24, 2019, 12:08:54 PM »
The primary just needs pins on the right spot so why not find that spot on the reverse side of the secondary spanner's "Y" and weld some in? :)

In the vid I had an old one I used on my Brute Force that I adjusted a bit but there's no reason one couldn't just flip the spanner and put another set on the other side..just round pins.
2015 Z Force 800 (53") EPS -
Custom Air Intakes | Custom Exhaust Mod | SuperATV Harness | Custom Fenders | Custom Skid/Rock Sliders | 27" GBC Grim Reapers | Seizmik Mirrors |Конструктор (Rodin's) Doors | Dr Pulley Sliders | 1.5" Wheel Spacers | BENZ Silencer (as needed) | SATV Flip Windshield W\ Rear Shield | Dual Light Bars | Diamond Plate Storage | 9.7" GPS | Bandit Springs Rear & Gen-3 Shocks Front

My Videos On YouTube

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Offline Sockman

Re: CLUTCH WORK - ZForce 800 Clutch R&R Plus Clocking Video!
« Reply #7 on: February 26, 2019, 09:24:14 AM »
This is what I ended up with.  Works great.  May never use it again!  The beauty of this is that the front of the bar tucks perfectly under one of the seat brackets, so you don't even have to hold it while tightening or loosening the nut for the driven pulley. 

If anybody wants to borrow it, just pay shipping back and forth and you're welcome to use it.
2017 Zforce 800 EX
UNI filter, SuperATV high clearance a-arms, half windshield, nerf bars, Windjammer rear window, overhead storage, Bighorns, Bandit suspension Gen3 shocks, rear camera

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Offline NMKawierider

Re: CLUTCH WORK - ZForce 800 Clutch R&R Plus Clocking Video!
« Reply #8 on: February 26, 2019, 10:19:22 AM »
Nice. Oh..trust me..you will use it again...and again...lol
2015 Z Force 800 (53") EPS -
Custom Air Intakes | Custom Exhaust Mod | SuperATV Harness | Custom Fenders | Custom Skid/Rock Sliders | 27" GBC Grim Reapers | Seizmik Mirrors |Конструктор (Rodin's) Doors | Dr Pulley Sliders | 1.5" Wheel Spacers | BENZ Silencer (as needed) | SATV Flip Windshield W\ Rear Shield | Dual Light Bars | Diamond Plate Storage | 9.7" GPS | Bandit Springs Rear & Gen-3 Shocks Front

My Videos On YouTube

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Offline Sockman

Re: CLUTCH WORK - ZForce 800 Clutch R&R Plus Clocking Video!
« Reply #9 on: February 26, 2019, 10:51:21 AM »
I did have a little trouble clocking the spring.  It took some doing to twist it into place before compressing the spring down.  Wondered if I was doing it wrong.  I think it was right, but just felt like a lot of tension to get it over and to stay in place.  Also, and this was dumb on my part, about lost my face taking it apart.  Thought the spring had let out the tension, so I zipped the pressure off with the impact.  Luckily I still had my hand on the thing and when it came loose, it really flew out of there.  Had to go change my shorts.
2017 Zforce 800 EX
UNI filter, SuperATV high clearance a-arms, half windshield, nerf bars, Windjammer rear window, overhead storage, Bighorns, Bandit suspension Gen3 shocks, rear camera

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Offline NMKawierider

Re: CLUTCH WORK - ZForce 800 Clutch R&R Plus Clocking Video!
« Reply #10 on: February 26, 2019, 11:04:29 AM »
I did have a little trouble clocking the spring.  It took some doing to twist it into place before compressing the spring down.  Wondered if I was doing it wrong.  I think it was right, but just felt like a lot of tension to get it over and to stay in place.  Also, and this was dumb on my part, about lost my face taking it apart.  Thought the spring had let out the tension, so I zipped the pressure off with the impact.  Luckily I still had my hand on the thing and when it came loose, it really flew out of there.  Had to go change my shorts.
Those springs have both torsion and compression so yeah..they can be deceptive.

Shouldn't have been too much to set the helix onto the pads. You always preload the spring in the direction that twists it inward (making it smaller) not outward (making it expand or larger) and the amount can be thought of as looking at a degree wheel and the chart. For example, looking at the chart-



B2 shows 38 degrees of preload so looking down on the helix (the parts with the ramps) think of looking down on a "degree wheel" and thinking of twisting the helix from the 12 o'clock position, zero, to 38 degrees to set it on the pad...just make sure that's the correct direction for twisting the spring..either way it has to go it will be 38 degrees from zero.


Some guys went too far...and others went backwards where other didn't set it at all.
« Last Edit: February 26, 2019, 12:29:02 PM by NMKawierider »
2015 Z Force 800 (53") EPS -
Custom Air Intakes | Custom Exhaust Mod | SuperATV Harness | Custom Fenders | Custom Skid/Rock Sliders | 27" GBC Grim Reapers | Seizmik Mirrors |Конструктор (Rodin's) Doors | Dr Pulley Sliders | 1.5" Wheel Spacers | BENZ Silencer (as needed) | SATV Flip Windshield W\ Rear Shield | Dual Light Bars | Diamond Plate Storage | 9.7" GPS | Bandit Springs Rear & Gen-3 Shocks Front

My Videos On YouTube

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Offline Sockman

Re: CLUTCH WORK - ZForce 800 Clutch R&R Plus Clocking Video!
« Reply #11 on: February 26, 2019, 11:31:03 AM »
Pretty sure I went inward with the spring, but I don't recall twisting it to the right.  So, if I went the wrong direction, wonder how the machine would act?
2017 Zforce 800 EX
UNI filter, SuperATV high clearance a-arms, half windshield, nerf bars, Windjammer rear window, overhead storage, Bighorns, Bandit suspension Gen3 shocks, rear camera

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Offline NMKawierider

Re: CLUTCH WORK - ZForce 800 Clutch R&R Plus Clocking Video!
« Reply #12 on: February 26, 2019, 12:24:49 PM »
Pretty sure I went inward with the spring, but I don't recall twisting it to the right.  So, if I went the wrong direction, wonder how the machine would act?
Probably won't shift...or will shift way too easy.
2015 Z Force 800 (53") EPS -
Custom Air Intakes | Custom Exhaust Mod | SuperATV Harness | Custom Fenders | Custom Skid/Rock Sliders | 27" GBC Grim Reapers | Seizmik Mirrors |Конструктор (Rodin's) Doors | Dr Pulley Sliders | 1.5" Wheel Spacers | BENZ Silencer (as needed) | SATV Flip Windshield W\ Rear Shield | Dual Light Bars | Diamond Plate Storage | 9.7" GPS | Bandit Springs Rear & Gen-3 Shocks Front

My Videos On YouTube

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Offline Sockman

Re: CLUTCH WORK - ZForce 800 Clutch R&R Plus Clocking Video!
« Reply #13 on: February 26, 2019, 12:31:19 PM »
I went back and reviewed the video.  I went the proper direction.  All good.
2017 Zforce 800 EX
UNI filter, SuperATV high clearance a-arms, half windshield, nerf bars, Windjammer rear window, overhead storage, Bighorns, Bandit suspension Gen3 shocks, rear camera

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Offline NMKawierider

Re: CLUTCH WORK - ZForce 800 Clutch R&R Plus Clocking Video!
« Reply #14 on: February 26, 2019, 12:40:11 PM »
I went back and reviewed the video.  I went the proper direction.  All good.
Cool..what did you go with..B2?
When I tried A2 I couldn't do it with my hand...has to enlist the help of my 24" stillson :)

« Last Edit: February 26, 2019, 12:43:33 PM by NMKawierider »
2015 Z Force 800 (53") EPS -
Custom Air Intakes | Custom Exhaust Mod | SuperATV Harness | Custom Fenders | Custom Skid/Rock Sliders | 27" GBC Grim Reapers | Seizmik Mirrors |Конструктор (Rodin's) Doors | Dr Pulley Sliders | 1.5" Wheel Spacers | BENZ Silencer (as needed) | SATV Flip Windshield W\ Rear Shield | Dual Light Bars | Diamond Plate Storage | 9.7" GPS | Bandit Springs Rear & Gen-3 Shocks Front

My Videos On YouTube