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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.

POLARIS Variable Transmission (PVT) System

WARNING

Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.


The PVT system rotates at high speeds, creating large amounts of force on clutch components. As the owner, you have the following responsibilities for your own safety and the safety of others:

  • Always follow all recommended maintenance procedures. Always look for and remove debris inside and around the clutch and vent system when replacing the belt.

  • See your dealer or other qualified service person as outlined in the owner's manual.

  • This PVT system is intended for use on POLARIS products only. Do not install it in any other product.

  • Always make sure the PVT housing is securely in place during operation.

Belt Removal/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. Place the transmission in park.

  2. Lift the cargo box.

  3. Remove the eight (8) fasteners securing the clutch cover 1. Each fastener can be removed using a 8mm 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. Mark the drive belt direction of rotation so that it can be installed in the same direction.

  7. Insert the clutch spreader tool into the threaded hole on the driven clutch as shown and turn clockwise to spread the clutch.

    NOTE

    Clutch spreader tool is part number 2883577.

  8. Walk the belt out of the driven clutch and drive clutch. Remove the belt from the vehicle.

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

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

  11. 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.).

Belt Installation

NOTE

Be sure to install belt in the same direction as it was removed.

  1. With the clutch spreader tool installed, loop the belt over the drive clutch and over the driven clutch.

  2. Rotate the driven clutch and walk the belt into the clutch.

  3. Turn the clutch spreader tool counterclockwise to remove from the driven clutch.

  4. Rotate / spin the driven clutch and belt approximately 5-7 times to properly seat the belt in the driven clutch.

  5. Install the clutch cover into wheel well by installing the top half first, then the bottom half over the suspension.

    NOTE
    Use care when installing the clutch cover. Do not damage cover, intake boot, or electrical harness.

  6. Install all clutch cover screws. Torque to specification.

    TORQUE

    PVT Outer Cover Fasteners: 44 in-lbs (5 N·m)

In this section:

  1. POLARIS Variable Transmission (PVT)
    System Drying