Drive Belt Installation - Polaris Sportsman 700 Efi 2005 Service Manual

Place another straight edge on top of
G
belt.
Measure the distance where the side
G
straight edges intersect the top, as
shown in the illustration.
Projected Belt
Width
Belt Width:
New 1.174 - 1.188" (2.98-3.02 cm)
Wear Limit 1.125" (2.86 cm)
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 continuously in one spot.
7. Measure belt length with a tape measure around
the outer circumference of the belt. Belts which
measure longer than nominal length may require
driven shimming or engine adjustment for a
longer center distance to obtain proper belt
deflection. Belts which measure shorter than
nominal length may require driven shimming or a
shorter center distance. Remember, proper belt
deflection is the desired goal - - not a specific
center distance.
8. Replace belt if worn past the service limit. Belts
with thin spots, burn marks, etc., should be
replaced to eliminate noise, vibration, or erratic
PVT operation. See Troubleshooting Chart at the
end of this chapter for possible causes.
Center
Distance
Clutch Center Distance -
10" +.1 / -.05
Belt Nominal Length - 40.875"± 3/16
(103.8 cm ± .48 cm)

DRIVE BELT INSTALLATION

Special Tool NOTE:Be sure to position belt so part
number is easily read. Verfiy new belt is seated
properly in the clutches before operating the ATV.
1. Loop belt over drive and over top of driven
sheave.
2. While pushing down on top of belt, turn the back
or moveable driven sheave clockwise.
3. The belt then should be able to be pushed down
into and between the sheaves.
4. Install clutch cover temporarily. Verify engine is in
PARK. Start engine and raise engine RPM
enough to engage the clutch, rotating the belt and
seating it in the clutches. Remove clutch cover
and verify belt is seated properly before final
cover installation.
CLUTCH
(254 +2.5 / -1.3mm)
6.17