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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 duct and from the clutch and engine compartments when replacing the belt. Allow the vehicle to cool before performing this procedure.

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

  1. Position the vehicle on a flat, level surface.

  2. Place the transmission in PARK.

  3. Stand clear and pull up on the cargo box release lever. Lift the front of the cargo box.

  4. Thoroughly clean all debris from the debris bracket 6 and from the engine compartment.

    NOTICE
    Some models may require the removal of additional panels to access the debris bracket.

  5. Loosen the air duct clamp 1 on the bottom of the air filter housing.

  6. Loosen the air duct clamp on the drive belt cover 2. Remove the air duct hose from the vehicle.

  7. Remove the upper cargo box shock pin, then remove the lower pin. Remove the shock from the vehicle.

    WARNING
    An unsupported or unstrapped box may fall if the cargo box shock is removed, and cause injury. Secure the box in place before attempting any work on the vehicle

  8. Remove the two fasteners that secure the lower cargo box shock mount to the vehicle frame. Remove the mount from the vehicle.

  9. Loosen all fourteen drive belt cover fasteners 3.

    NOTICE
    Do not remove the fasteners from the drive belt cover.

  10. Remove the drive belt cover 4 from the vehicle. Pivot the rear of the cover up to remove.

  11. Inspect the cover seal on the clutch housing for wear or damage. Replace if necessary.

  12. Mark or note the direction of the PVT drive belt. The belt must be installed in the same direction if the belt will be reinstalled.

  13. Insert the clutch spreader tool 5 into the threaded hole on the driven clutch. Turn the spreader tool clockwise to spread the clutch.

    NOTICE
    If the tool does not readily turn, rotate the driven clutch one quarter of a turn counterclockwise. Repeat the above step.

  14. Remove the belt from the driven clutch.

    TIP
    Removing the belt from the bottom of the driven clutch first can help provide additional clearance for belt removal.

  15. Inspect the belt for any fraying, hour-glassing, loose cords, missing cogs, abrasions, burns, or damage. Replace if needed.

  16. Clean the inside of the drive belt covers thoroughly and ensure that all debris from the air duct is removed.

  17. 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.).

  18. Loop the new belt over the drive clutch, and begin to install it over the driven clutch sheave. Then, remove the clutch spreader tool from the driven clutch.

  19. Rotate the driven clutch clockwise five to seven times to help seat the belt onto the sheaves.

  20. Reinstall the drive belt cover. Torque the fasteners to specifications.

    PVT Outer Cover Fasteners
    35 in-lbs (4nm)

  21. Reinstall the lower cargo box shock mount. Torque the fasteners to specifications.

  22. Reinstall the cargo box shock into both the upper and lower mounts.

  23. Reinstall the air duct to both the airbox and the drive belt cover. Torque the clamps to specifications.

Parent topic: POLARIS Variable Transmission (PVT) System