Required Tools and Supplies:
- 8mm Socket
- Ratchet
- Torque Wrench
- Clutch Spreader Tool
- Eye Protection
- Nitrile Gloves
- Shop Rags
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.
To inspect and replace the drive belt on your RZR XP S, follow these steps:
1. Park the vehicle on a flat, level surface, ensure it is in PARK, and remove the key.
2. On two-seat models, remove both seats. On four-seat models, remove the rear passenger seats.
3. Begin by thoroughly cleaning all debris from the engine compartment. Note: The cargo box was removed for visual purposes.
4. Move to the driver side rear wheel well and loosen the clamp fastener that secures the PVT inlet duct to the outer clutch cover using an 8mm socket.
5. Remove the hose from the clutch cover. Tip: Loosen top clamp fastener and position the hose out of the way. Note: PVT hose removed for visual purposes.
6. Loosen the 14 clutch cover fasteners with an 8mm socket.
7. Slide the cover outward until it hits the shock spring, rotate the cover downward and slide the cover down underneath the skid plate. Tip: Keep the retained fasteners pulled out as much as possible to ease the removal.
8. Once complete, inspect the cover seal for wear or damage, and replace it if necessary. A new cover seal is part number 5526344.
9. Before continuing, 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. Note: Tool provided in vehicle tool kit.
11. Carefully walk the belt off the driven clutch and remove it from the drive clutch.
12. Continue by inspecting the belt for any fraying, hour-glassing, loose cords, missing cogs, abrasions, burns or damage, and replace if needed. A new drive belt is part number 3211186.
13. Clean the inside of the clutch covers thoroughly.
14. Clean the area around the clutches thoroughly to prevent damage to vehicle components. Tip: 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. Once complete, reinstall the clutch cover by maneuvering around the frame and over the drive clutch.
20. Install the 14 clutch 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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