Belt Inspection; Belt Installation; Pvt Break-In (Drive Belt / Clutches) - Polaris 2009 Sportsman XP 850 Service Manual

CLUTCHING (PVT)

Belt Inspection

1. 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.
2. Inspect belt for loose cords, missing cogs, cracks,
abrasions, thin spots, or excessive wear. Compare belt
measurements with a new drive belt. Replace if necessary.
3. Belts with thin spots, burn marks, etc., should be replaced
to eliminate noise, vibration, or erratic PVT operation. See
the Troubleshooting Chart at the end of this chapter for
possible causes.

Belt Installation

1. If the Belt Removal Tool was removed without the belt
installed, you must rotate the clutch and insert the tool at
the 6 o'clock position.
2. With the Belt Removal Tool installed, loop the belt over the
drive clutch and over top of the driven sheaves.
NOTE: Be sure to install the drive belt as shown, so
the "Polaris" label can be read .
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3. Rotate the driven sheave and walk the belt into the driven
clutch.
4. Replace the outer PVT cover seal.
5. Reinstall outer PVT cover and secure with screws. Torque
screws to specification.
Outer PVT Cover Screws:
45-50 in. lbs. (5-5.6 Nm)
6. Reinstall the lower left-hand frame support and torque bolts
to specification.
Lower Left-Hand Frame Support Bolts:
36 ft. lbs. (49 Nm)
7. Install the left rear wheel and torque wheel nuts to
specification.
Wheel Nuts:
Steel: 45 ft. lbs. (61 Nm)
Aluminum: 75 ft. lbs. (102 Nm)
8. Lower the ATV, start the engine, and test the operation of
the PVT system.

PVT Break-In (Drive Belt / Clutches)

A proper break-in of the clutches and drive belt will ensure a
longer life and better performance. Break in the clutches and
drive belt by operating at slower speeds during the 10 hour
break-in period as recommended (see Chapter 5 "Engine
Break-In Period" for break-in example). Pull only light loads.
Avoid aggressive acceleration and high speed operation during
the break-in period.
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