HOW TO REPLACE YOUR POLARIS MACHINE BELT If a belt fails on your Polaris RZR 800, RZR 4 800, RZR S 800, RZR S, RANGER RZR or RANGER RZR S, 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. REMOVE SEAT, CLUTCH COVER, AND DEBRIS 1. Remove the seat and the under-seat storage box. 2. Remove the clutch cover screws with an 8mm Allen socket 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. OPEN CLUTCH SHEAVES TO REMOVE AND INSTALL BELT 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. 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.On EBS models, with the belt removal 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. 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. TIGHTEN CLUTCH SHEAVES AND FINISH INSTALL 7. 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. 8. 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. How to Replace Your Polaris Machine Belt Remove Seat, Clutch Cover, and Debris Open Clutch Sheaves to Remove and Install Belt Tighten Clutch Sheaves and Finish Install WHY REPLACE YOUR BELT? An old or damaged belt may damage other components in the clutch box, and a worn belt will cause jerky drive-away, false misfire and accelerated wear of clutch bushings. HOW TO BREAK-IN YOUR BELT Inspect and clean debris from the clutch covers, ducting and engine compartment. Remove any rubber residue from sheaves by scuffing with a pad. Clean sheaves with evaporating degreasing solvent like rubbing alcohol, or brake cleaner. Finish by driving in low gear and avoid high RPMs for first 5 miles (8 km) MINIMUM of operation. WHEN TO REPLACE YOUR BELT If you find cracks, loose cords, or missing cogs, if drive-away and engagement has gotten “jerky”, or any “hour-glassing” where a section has worn narrower, it’s time for a new belt. At Polaris, we take great pride in our history as a category pioneer and current position as the global industry leader in powersports. We have proudly defined, re-defined and then raised the bar again for the powersports industry. Polaris is powering passion and pioneering new possibilities for all those who play, work and THINK OUTSIDE.