Polaris Ranger Secondary Clutch Problems [5 Issues Solved!]

If you’re the owner of a Polaris Ranger, then you know that this vehicle is packed with features and power. However, you may not know that these vehicles have some common problems with the secondary clutch system.

In this article, we’ll discuss five Polaris Ranger secondary clutch problems  – and how to solve them!

Wearing and overheating clutch alongside loose pedals are the most common problems that can happen. Furthermore, vibrating pressure plates and dirt and debris buildup on the clutch are also usual issues you can face. The solutions in terms of cleaning, repair, and replacements are simple. 

Let’s get moving, then, with detailed overviews!

What Happens When Problems With Secondary Clutches Appear?

Rebuild A Polaris Clutch

There can be various consequences when problems with secondary clutches appear on Polaris Ranger vehicles. One possible outcome is that the rider will not be able to move at all, which can cause a lot of inconvenience.

In another scenario, the UTV will still be able to move, but it will not be able to shift gears properly. This can lead to decreased performance and efficiency, and it may also damage other components. 

How Do I Know If My Polaris Secondary Clutch Is Bad?

There are a few things you can look for to determine if the Polaris Ranger secondary clutch is terrible. A prevalent symptom is that the UTV will not move when you try to accelerate.

Another sign that the clutch may be bad is if you hear a grinding noise when the UTV is in gear. If you suspect the Polaris Ranger UTV secondary clutch is bad, it is best to take it to a mechanic to inspect it.

5 Secondary Clutch Problems In Polaris Rangers

Wearing ClutchDecreased PerformanceReplace The Clutch
Overheating ClutchLoss Of Power TransferAdjust The Tension Or Replace It
Loose Clutch PedalClutch Spring Issues In The Mechanical UnitTighten The Clutch Springs
Vibrating Pressure PlateDifficult To Engage Clutch PedalRepair Entire Clutch Assembly
Dirt Or Debris Build-UpAbnormal NoisesClean The System

If you’re the owner of a Polaris Ranger, then you know that it’s a workhorse. But with all that power and torque comes the potential for serious problems with the secondary clutch. We will look deeper at five of the most common issues and how to fix them.

Problem 1: Wearing Clutch

The secondary clutch may wear out over time and need to be replaced. One of the main reasons that secondary clutches on vehicles wear out is that they are often subjected to great stress.

This stress can be caused by various factors, such as using the clutch in stop-and-go on bumpy terrains or while accelerating quickly.

Additionally, the constant abrasion against the flywheel can also cause undue wear and tear on the clutch.

Symptom: Decreased Performance

As the secondary clutch wears, the spring, weights, and helix can become less effective at transferring power from the engine to the drivetrain. This can cause the engine to work harder than it should, leading to decreased power and acceleration.

Solution: Replace The Clutch

To replace the secondary clutch inside, you have to remove the old clutch first. This can be done by removing the bolts that hold it in place. Once the old clutch is removed, the new one can be installed.

The new clutch must be installed in the same position as the old one. This can be done by using the marks that are on the flywheel. The bolts must be tightened to the correct torque specifications.

Once the bolts are tightened, the engine must be test run to ensure everything is working correctly.

Problem 2: Overheating Clutch

The main reason a secondary clutch overheats is that it’s not getting enough air. This can be due to several reasons, such as the Polaris Ranger bumping too often or the clutch not being released properly.

Symptom: Loss Of Power Transfer

When this device overheats, it can cause significant damage to the engine and the entire vehicle. Symptoms of an overheating secondary clutch include a burning smell, loud noises, and sudden loss of power due to slipping.

Solution: Adjust The Tension Or Replace It

Too much or too little tension can cause problems with the vehicle’s performance, so you need to adjust it. To do the job, three different things can be done:

  • Use a clutch alignment tool to adjust the position of the clutch plate
  • A clutch cable adjustment tool can also be used to adjust the tension on the cable
  • Alternatively, you can adjust the clutch pedal height to change the tension on the spring.

If these processes do not solve the problem, replace the secondary clutch. 

Problem 3: Loose Clutch Pedal


A few things can cause a loose clutch pedal inside the Polaris Ranger. More commonly, there may be air trapped in the hydraulic system, which can be caused by a leak in the line.

Other than that, the clutch linkage may be worn or corroded, not providing a solid connection between the pedals and the clutch.

Symptom: Clutch Spring Issues In The Mechanical Unit

The clutch spring gets loose inside a vehicle because the bearing it rides on starts to wear. As the bearing wears, it allows the clutch spring to move more and more freely.

Eventually, the clutch spring will come completely out of its groove, and the vehicle will no longer be able to move.

Solution: Tighten The Clutch Springs

Tight Clutch Springs In Polaris Ranger Secondary Clutch

The process of tightening the clutch spring inside a vehicle is relatively simple. First, locate the clutch spring and identify the bolt that holds it in place. Then use a wrench to loosen the bolt and remove the clutch spring.

Finally, reattach the clutch spring using the wrench to tighten the bolt.

Problem 4: Vibrating Pressure Plate

The cause of a vibrating pressure plate is something wrong with the flywheel, such as a crack or warp. If the flywheel is not aligned correctly with the crankshaft, it can also cause the pressure plate to vibrate.

Symptom: Difficult To Engage Clutch Pedal

The clutch pedal is difficult to engage when the pressure plate vibrates because the vibrations make it harder to press down on the pedal.

This can cause the driver to stall the vehicle or have trouble shifting gears.

Solution: Replace Entire Clutch Assembly

A good solution for fixing vibrating pressure plates on secondary clutches in a vehicle is to replace the entire clutch assembly. This will ensure that the pressure plate is properly aligned and will help to alleviate any vibration or rattling that may be occurring.

Also, ensuring that the clutch disc and flywheel are in good condition and properly lubricated is important. These parts can be lubricated with engine oil which can help to keep the friction between the surfaces to a minimum.

Problem 5: Dirt Or Debris Build-Up

Dirt and debris can accumulate on the clutch disc, flywheel, and pressure plate. This can cause the clutch to slip and eventually fail. The build-up can look like thick black sludge.

Symptom: Abnormal Noises

The noises that a dirty clutch makes inside a vehicle can be quite strange and unsettling. When the clutch is dirty, it can create a grinding noise when it is engaged.

This noise can be very loud and distracting, and it can also be damaging to the clutch itself.

Solution: Clean The System

To clean the clutch disc, flywheel, and pressure plate inside a vehicle, the first step is to remove them from the system. The flywheel can be removed with a wrench, and the pressure plate can be removed with screws.

Once they are removed, they can be cleaned by spraying clutch cleaners. The parts should be dried before being reassembled in the vehicle. 


What to do to prevent clutch problems on Polaris Ranger?

To prevent clutch problems on Polaris Ranger UTVs, keeping the clutch system clean and well-lubricated is important. Make sure to check the oil level regularly and top off as needed. You should also inspect the belt for damage and replace it if necessary.

What to do if the secondary clutch is spinning too fast?

If the secondary clutch is spinning too fast, the gears will grind, and the engine will overheat. To prevent this, the rider should shift to a lower gear and then stop to inspect the issue inside. 

How long do secondary clutches last?

UTV secondary clutches can last anywhere from 1,000-10,000 miles, depending on the make and model of the vehicle. Generally speaking, the more expensive UTVs will have longer-lasting secondary clutches, while cheaper models may need to be replaced more often.


There can be 5 Polaris Ranger secondary clutch problems depending on specific symptoms. It is always good to extensively maintain your vehicle and its inner functions more often. You may be saving a lot on repairs with this.

It’s time to go, till then, goodbye!


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