Polaris RZR: How to Replace a Drive Belt

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The drive belt on a Polaris RZR connects the secondary on the engine to the clutch. This allows the engine to turn the clutch, which engages the transmission. If this belt should fail, the ATV can't drive anywhere. To fix the issue, you need to replace the drive belt, which takes about 30 minutes.

Things You'll Need

  • 3/8-inch ratchet and socket set
  • Torx-bit set
  • Open-end wrench set
  • 6-inch 3/8-inch extension
  • 3/8-inch female to 1/2-inch male socket converter
  • Replacement belt
  • Shift the RZR into neutral using the shifter. Pull the seat off of the top of the RZR with your hands. Pull off the heat shield cover behind the seat belt with your hands, and then unbolt the seat belt mount from the chassis using a 3/8-inch ratchet and socket and an open-end wrench. Unbolt the seat belt bar from the plastic console in the RZR with the 3/8-inch ratchet and a Torx-head bit. Remove the seat belt bar from the RZR.

  • Remove the clutch cover with the 3/8-inch ratchet and socket. Install the 3/8-inch to 1/2-inch adapter onto the 3/8-inch extension. Locate the secondary, which is on the right side of the assembly. Insert the extension assembly into the side of the secondary and push the extension towards the engine. Pull the belt over the secondary, and then rotate the belt over the secondary.

  • Route the replacement belt over the clutch and then over the secondary. Push in the extension assembly again on the secondary, and then rotate the belt onto the clutch and secondary.

  • Reassemble the clutch cover and seat belt bar into the chassis with the 3/8-inch ratchet and socket, an open-end wrench and a Torx-head socket. Reinstall the heat shield by pushing it into place.

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