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IMPORTANT

The Owner's Manual for this vehicle contains warnings, instructions and other information you must read and fully understand before safely riding or performing maintenance on this vehicle. Always follow the warnings and instructions in Owner's Manual.

Click the link above for the Table Of Contents, or download a full PDF of the Owner Manual in the Owner Support area of Polaris.com.

Belt Replacement / Debris Removal

If a belt fails, always clean any debris from the clutch air duct and from the clutch and engine compartments when replacing the belt.

WARNING
Failure to remove ALL debris when replacing the belt could result in vehicle damage, loss of control and severe injury or death.

To replace the belt, do the following:

  1. Position the vehicle on a level surface. Block the wheels to prevent vehicle movement. Place the transmission in neutral.

  2. Lift the cargo box.

  3. Remove the clutch cover 1 using a 3/8” socket with ratcheting wrench and extension.

  4. Pull the bottom of the cover outward and over the suspension to remove it.

  5. Make sure the cover gasket does not fall out of the groove when removing the cover.

  6. Squeeze the belt 2 together so that it submarines further into the driven clutch, creating slack in the belt between the clutches.

  7. Remove the belt by using the slack to pull part of the belt off the driven clutch.

  8. Rotate the driven clutch by hand until the belt is completely off.

  9. Slide the front of the belt out from between the drive clutch and inner clutch cover to completely remove it.

  10. Remove all debris wrapped in and around the PVT system.

  11. Remove all debris from the entire clutch air duct passage.

  12. Check for signs of damage to seals on the transmission and engine. If any seals appear to be damaged, your vehicle requires prompt service. Your POLARIS dealer can assist.

    TIP
    Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail. Switch to low range while operating at slower speeds to extend the life of the PVT components (belt, cover, etc.).

  13. To install a belt, place one end of the belt over the driving clutch. Route the belt over the top of the driven clutch and down into the groove of the clutch to allow slack in the belt. Rotate the driven clutch by hand until the belt falls into place.

  14. Reinstall the clutch cover in the reverse order of removal, fitting the top of the cover into place, then working the bottom of the cover over the suspension.

  15. Install all clutch cover screws. Torque to 4-5 ft. lbs. (5.5-6.5 Nm).

Parent topic: POLARIS Variable Transmission (PVT) System