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POLARIS GOVERNMENT & DEFENSE
HELP CENTER
09/12/2023

2024 RZR XP Drive Belt Inspection and Replacement

Required Tools and Supplies

  • 8mm Socket
  • Ratchet 
  • Torque Wrench
  • Clutch Spreader Tool
  • Safety Glasses
  • Nitrile Gloves
  • Shop Rags

For information on tools, read the Tools and Fasteners Guide. Always wear safety glasses and nitrile gloves when servicing your RZR XP. Note: Drive belt maintenance should only be performed after the vehicle has completely cooled.

To inspect or replace the drive belt on your RZR XP, follow these steps:

1. Park the vehicle on a flat, level surface, ensure it is in PARK and remove the key.

2. Clean any dirt or debris from the engine compartment.

3. Move to the driver side rear wheel well and loosen the clamp fastener with an 8mm socket. Remove the hose from the clutch cover and position the hose out of the way.

4. Loosen the fourteen retained cover fasteners with an 8mm socket.

5. Slide the clutch cover outward until it hits the shock spring.

6. Rotate the cover downward. Tip: Keep the retained fasteners pulled out as much as possible to ease the removal.

7. Slide the cover down underneath the skid plate. Note: For easiest removal, ensure 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. 

8. Inspect the cover seal for wear or damage and replace if necessary. A new cover seal is part number 5526344.

9. Take note of the drive belt direction of rotation. The belt must be installed in the same direction if reusing.

10. Insert the clutch spreader tool into the driven clutch. Turn the tool clockwise to open the sheaves.

11. Carefully walk the belt off the driven clutch and remove from the drive clutch.

12. Inspect the belt for any fraying, hour-glassing, loose cords, missing cogs, abrasions, burns or damage, and replace if needed. A new belt is part number 3211186.

13. Clean out the inside of the clutch covers thoroughly. 

14. Clean the area around the clutches thoroughly to prevent damage to vehicle components. Tip: A mobile device can be used to see behind the clutches. Any sign of oil leaks indicates that debris may be trapped behind the clutches.

15. If replacing the belt, the part number on the belt should face outward when installed.

16. Loop the belt over the drive clutch and begin working it over the driven clutch sheave while spreading the sheave as needed with the spreader tool.

17. Remove the clutch spreader tool.

18. Rotate the clutch five to seven times to help seat the belt on the sheaves.

19. Reinstall the clutch cover by maneuvering around the frame and over the drive clutch. 

20. Install the fourteen retained cover fasteners, and torque to 4.4 ft-lbs (6 Nm).

21. Reinstall the PVT inlet duct to the outer clutch cover and fasten until fully seated.

For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.

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