Drive Belt Removal/Inspection - Polaris Sportsman 400 Service Manual

DRIVE BELT REMOVAL/INSPECTION

1. Remove outer PVT cover as described in PVT
Disassembly.
2. Mark drive belt direction of rotation so that it can be
installed in the same direction. NOTE: Normally
positioned so part numbers are easily read.
3. To remove drive belt, apply brake, pull upward and
rearward on belt to open driven clutch sheaves, pull
out and down on belt to slip over the driven clutch
outer sheave.
4. Measure belt width and replace if worn severely.
Generally, belt should be replaced if clutches can no
longer be adjusted to provide proper belt deflection.
S The top edges have been trimmed on some
drive belts. It will be necessary to project the
side profiles and measure from corner to corner.
S Place a straight edge on each side of the drive
belt.
S Place another straight edge on top of belt.
S
Measure the distance where the side straight
edges intersect the top, as shown in the illustra-
tion at right.
5. Inspect belt for loose cords, missing cogs, cracks,
abrasions, thin spots, or excessive wear. Replace if
necessary.
6. Inspect belt for hour glassing (extreme circular wear
in at least one spot and on both sides of the belt).
Hour glassing occurs when the drive train does not
move and the drive clutch engages the belt.
Belt Width:
New 1.174 - 1.188"
(2.98-3.02 cm)
Wear Limit 1.125" (2.86 cm)
- projex@inbox.lv -
CLUTCH
Projected Belt
Width
6.19