POLARIS OFF-ROAD VEHICLES

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Belt Change for RZR®

If a belt fails on your Polaris® RZR, always clean any debris from the PVT intake and outlet duct and from the clutch and engine compartments when replacing the belt. Failure to remove all debris when replacing the belt could result in vehicle damage, loss of control and severe injury or death.

Allow hot components to cool before changing the belt on your RZR. When installing a new belt, position the belt so the part number can be easily read.

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.).

Note that belt change procedures are the same for two-seat and four-seat models.

When removing clutch cover screws, use an 8mm Allen socket.

RZR 900, S 900, XP 900, S 1000 and XP 1000 Belt Change
1. Remove the engine access cover and thoroughly clean all debris from the aluminum debris basket (1) and from the engine compartment.

Debris belt basket

2. Remove the clutch cover screws and open the clutch cover (It does not have to be removed from the vehicle). Remove all debris wrapped in and around the PVT system. Use the shock/clutch tool from the tool kit to slightly open the sheaves to aid in debris removal and belt installation. Insert the hooked end of the tool, as shown below. Apply force to the opposite end of the tool to spread the sheaves. Walk the belt out of the driven clutch and drive clutch. Remove the belt from the vehicle.

Clutch tool

3. Remove all debris from the entire clutch air duct passage (2).

Air duct passage

4. Check for signs of damage to seals on the transmission and engine. See your POLARIS Dealer promptly for service if any seals appear to be damaged.

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

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

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

8. Rotate/spin the driven clutch and belt approximately five to seven times to properly seat the belt in the driven clutch.

9. Install the outer clutch cover and screws. Torque the screws to 54 in-lbs (5 Nm) on RZR 900 and S 900 models. Torque to 45 to 50 in-lbs (5.5 Nm) on RZR XP 900. Torque to 48 in-lbs (5 Nm) on RZR XP 1000.

RZR XP Turbo
1. Remove the engine access panel and thoroughly clean all debris from the engine compartment. Removal of the left rear wheel or shock is not necessary for belt replacement.

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

3. Remove the eight clutch cover screws (2).

Clutch cover

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

5. Mark the drive belt direction or 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.

Spreader tool

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.

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 five to seven times to properly seat the belt in the driven clutch.

16. Install the outer clutch cover and screws. Torque screws to 35 in-lbs (3 Nm).

RZR XP Turbo S
1. Remove the engine access panel and thoroughly clean all debris from the engine compartment. Removal of the left rear wheel or shock is not necessary for belt replacement.

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

3. Remove the nine clutch cover screws (2).

Clutch cover

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

5. Mark the drive belt direction or rotation so that it can be installed in the same direction if being reinstalled.

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

Spreader tool

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.

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 five to seven times to properly seat the belt in the driven clutch.

16. Install the outer clutch cover and screws. Torque screws to 35 in-lbs (3 Nm).

RZR Pro XP
1. Remove the engine access panel and thoroughly clean all debris from the engine compartment. 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 14 clutch cover screws (2).

Clutch cover

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.

Clutch spreader tool

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 the 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 five to seven times to properly seat the belt in the driven clutch.

16. Install the outer clutch cover and 14 fasteners (1). Torque fasteners to 36 in-lbs (4 Nm).

Clutch cover

17. Install the PVT intake hose, and torque the hose clamp (2) to 25 in-lbs (3 Nm).

RZR 570
1. Remove the clutch cover screws (1) and open the clutch cover. Remove all debris wrapped in and around the PVT system.

Clutch cover

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

3. 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.

4. On Non-EBS models, loosen the driven clutch retaining belt to help spread the clutch sheaves.

Driven clutch retaining belt

On EBS models, insert the clutch spreader tool into the driven clutch, as shown below. Then rotate the tool toward the clutch to open the sheaves.

Clutch spreader tool

5. Remove the belt from the drive and driven clutches.

6. Be sure to install the belt in the same direction as it was removed. On Non-EBS models, loosen the driven clutch retaining bolt to help spread the clutch sheaves. On EBS models, insert the belt removal tool into the driven clutch as shown below and loop the bolt over the driven clutch sheave.

Clutch tool

Rotate the tool toward the clutch to open the sheaves.

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

8. Rotate/spin the driven clutch and belt approximately five to seven times to properly seat the belt in the driven clutch.

9. For non-EBS models, torque the driven clutch retaining bolt to 43 lb-ft (58 Nm).

10. Install the outer clutch cover and bolts. Torque bolts to 100 in-lbs (12 Nm).

RANGER RZR, RZR S, RZR 800, RZR S 800
1. Remove the seat and the under-seat storage box.

2. Remove the clutch cover screws and open the clutch cover. Remove all debris wrapped in and around the PVT system.

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

4. Check for signs of damage to seals on the transmission and engine. See your POLARIS Dealer promptly for service if any seals appear to be damaged.

5. On standard non-EBS models, place the transmission in PARK and push down on the belt firmly to open the clutch sheaves. Then lift upward on the belt while pulling it out and down over the driven clutch outer sheave.

Belt removal

On EBS models, insert the belt removal tool into the driven clutch as shown below. Rotate the tool toward the clutch to open the sheaves. Walk the belt out of the driven clutch and drive clutch. Remove the belt from the vehicle.

Clutch tool

6. On standard non-EBS models, loop the belt over the drive clutch and over the driven sheave. While pushing down on the top of the belt, turn the back or moveable driven sheave clockwise. The belt should be able to be pushed down into and between the sheaves. Continue rotating the driven clutch and belt clockwise until the belt is fully installed.

On EBS models, with the belt removal tool installed, loop the belt over the drive clutch and over the driven clutch. Rotate the driven clutch and walk the belt into the clutch. Remove the belt removal tool from the driven clutch. Rotate/spin the driven clutch and belt approximately five to seven times to properly seat the belt in the driven clutch.

RS1
For a full description of how to change the belt, click here.

For more maintenance procedures, tips and specifications, consult your Owner's Manual. To access your Owner's Manual online, click here.
To view a parts catalog, click here.