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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 Removal and Replacement

If a belt fails, always clean any debris from the outlet 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.
TIP

  • Wiggling and rocking the cover will help it move around the bolts on the clutch towers.

  • Make sure the clutch cover bolts are not catching on other parts.

  • Rotating the drive clutch slightly by hand can provide more clearance in some cases.

  • For easiest removal, make sure the vehicle is sitting on the ground at normal ride height or lower, which will provide more clearance between the cover and the shock absorber. Turning the drive clutch slightly by hand can also help provide more room for removal.

  • If reinstalling the belt, reference the print on the belt to reinstall in the same direction.

NOTICE
Drive belt maintenance should only be performed after the vehicle has completely cooled.

  1. Allow hot components to cool before performing this procedure.

    NOTE
    If the vehicle is on solid ground, removal of the left rear wheel or shock is not necessary for belt replacement. If the vehicle is on a lift, the shock must be removed in order to remove the clutch cover.

  2. Loosen the clamp 1 retaining the PVT inlet duct to the outer clutch cover.

  3. Remove the fourteen (14) clutch cover screws 2.

  4. Maneuver the outer clutch cover outward to access the drive belt.

  5. Mark the drive belt direction of rotation so that it can be installed in the same direction.

  6. Insert the clutch spreader tool 3 into the driven clutch. The tool is provided in the tool kit.

  7. Turn the tool clockwise to open the sheaves on the driven clutch.

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

  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.

  12. With the clutch spreader tool installed, loop the belt over the drive clutch and over part of the driven clutch. Be sure to install belt in the direction previously marked.

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

  14. Remove the clutch spreader tool from the driven clutch.

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

  16. Install the outer clutch cover and fourteen fasteners 1. Torque fasteners to specification.

    TORQUE

    Outer Clutch Cover Fasteners:

    53 in-lbs (6 N·m)

  17. Reattach the PVT inlet duct to the outer clutch cover (and fasten with the clamp).

    TORQUE

    PVT Intake Hose Clamp:

    27 in-lbs (3 N·m)

TIP
Belt slip is responsible for creating excessive heat that wears belts, 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.). Prolonged operation with heavy loads or at high speeds can shorten belt life.
Parent topic: POLARIS Variable Transmission (PVT) System