Thanks for the history on your Rangers. You truly work them and take better care than most owners do. Glad to hear everything else is holding up for your machines.
My 2014 900 XP has almost 3000 mi on the clock and I am noticing more and more noises which indicate my secondary is acting up. Sometimes at about 10 mph I'll get this "ticking" sound that sounds like something in the secondary isn't pinching the pulley evenly, all the way around. Sometimes, it's quiet. I am just waiting for the Fall to do a DuraClutch on mine. From what I am reading, the OEM 900 set-up lasts no more than 4000mi before something goes. The DuraClutch should
give you much better life.
As I understand it, the DuraClutch was designed by former Polaris engineers who recognized the limitations of using the belt as your clutch. In a 4hp minibike that set-up is fine. In a 60-80hp ute, pulling a 500 lb trailer, that is not the best solution hence, the DuraClutch. By keeping the belt engaged and by not slipping the belt, the whole assembly sees less stress and the belt lasts longer.
As for the inner parts on the pulleys, I have asked the folks at DuraClutch about the design of the cams and pulley plates and how they differ from the OEM design. I hope to hear back from them shortly and will post what they report.
What you described about your secondaries being trashed is very common. The OEM unit is evidently aluminum to aluminum contact between the cams and the one sliding pully side. You cannot lube these parts because they spin at pretty high rates of speed and no lube would stay where its needed. I am hoping the DuraClutch has a better weight/cam design that lasts a little longer than the OEM.
I drive my 900 XP on my ranch and it rarely sees above 10 mph except when I run to town or haul the dogs for a ride. The transmission aside, I have never seen another brand with the simple ergonomics and rugged design features found in the Polaris Ranger series. The thought of a real clutch and geared transmission like the Honda sounds nice but, the simplicity of the automatic twin pulley system improved by the DuraClutch is hard to beat. The motors easily run 10,000 mi with service, and beyond. The suspensions are very robust except for suspension bits that wear. Doing replacement on the outer wheel bearings and half-shafts appears very straight forward. Parts aren't that expensive so running yours 5-10,000 mi should be practical.
Stay tuned. I'll post their response...
Here is where they post answers to questions on the DuraClutch...