Required Tools and Supplies
- T27 TORX® Socket
- 10mm Socket
- 11mm Wrench
- Ratchet
- Torque Wrench
- Multi-Function Pliers
- Eye Protection
- Nitrile Gloves
- Shop Rags
For information on tools, read the Tools and Fasteners Guide. Always wear safety glasses and nitrile gloves when servicing your Polaris Sportsman.
To inspect or replace the drive belt on your Sportsman X2, Touring and 6x6 570, follow these steps:
1. Park the vehicle on a flat, level surface, ensure it is in park and set the parking brake.
2. Lift up on the passenger seat lever and remove.
3. Pull up on the rear of the driver seat and pull the seat back and free of the tabs.
4. Remove the three push-pin rivets securing the left side panel with a multi-function pliers.
5. Grab the rear of the side panel and with a firm motion, pull the side panel outward to disengage the side panel from the vehicle.
6. Remove the lower panel.
7. Remove the two screws with a T27 TORX® and two push-pin rivets with a multi-function pliers from the footwell.
8. Remove the six screws and nuts from the bottom of the footwell with a T27 TORX® and 11mm wrench. Pull the footwell downward and outward to remove.
9. Remove the three fasteners from the rear passenger foot support bracket with a 10mm socket.
10. Remove the 10 fasteners securing the outer PVT cover to the inner PVT cover with a 10mm socket.
11. Using care, pull the outer PVT cover out the side of the vehicle.
12. Remove the three inner PVT cover fasteners with a 10mm socket.
13. Note the orientation of the drive belt so that it can be installed in the same direction.
14. Insert the clutch spreader tool, included in your tool kit, into the threaded hole on the driven clutch and turn clockwise to spread the clutch.
15. Carefully walk the belt off the driven clutch and remove from the drive clutch.
16. Inspect the belt for hour glassing. Hour glassing occurs when the drive train does not move, and the drive clutch engages the belt.
17. Inspect the belt for loose cords, missing cogs, cracks, abrasions, thin spots or excessive wear. Compare belt measurements with a new drive belt and replace, if necessary.
18. Belts with thin spots, burn marks, etc. should be replaced to eliminate noise, vibration, or erratic PVT operation. See General Diagnostic information for possible causes in your Owner's Manual.
19. Clean out the inside of the clutch covers thoroughly. Warning: Failure to remove all debris when replacing the belt could result in vehicle damage, loss of control and severe injury or death.
20. If replacing the belt, orient the belt as it was removed or orient the new belt so that you can read the text. A new drive belt is part number 3211229.
21. With the clutch spreader tool installed, loop the belt over the drive clutch and over the driven clutch.
22. Rotate the driven clutch and walk the belt into the clutch.
23. Once the belt is installed, turn the clutch spreader tool counterclockwise to remove from the driven clutch.
24. Rotate the driven clutch and belt approximately 5-7 times clockwise to properly seat the belt into the driven clutch.
25. Reinstall the inner PVT air duct cover fasteners and torque to 44 in-lbs (5 Nm).
26. Reinstall the outer PVT cover and 10 fasteners and torque to 44 in-lbs (5 Nm).
27. Reinstall the passenger footrest bracket and torque to 89 in-lbs (10 Nm).
28. Carefully install the footwell onto the vehicle and loosely install the six screws and nuts into the bottom of the footwell.
29. Loosely install the two screws and two push-pin rivets into the footwell. Note: Observe the condition of each push-pin rivet and check for damage. If damaged, Polaris recommends that you replace the push-pin rivet before installation.
30. Install the side panel onto the vehicle and install the three push-pin rivets.
31. Torque footwell to chassis fasteners to 3 in-lbs (4 Nm). Torque footwell to rear cab screws until fully seated.
32. Reinstall the seats.
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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Unless noted, trademarks are the property of Polaris Industries Inc.
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