How to Change Drive Belt on Polaris Sportsman 500

Knowing how to change belt on Polaris Sportsman is critical for optimizing your ATV’s performance and reliability during operation. Yet, many enthusiasts have trouble removing and replacing them due to their complex nature and specific installation requirements. So, do you know how to change drive belt on Polaris Sportsman 500?

In this article, we’ll elaborate on every step required for removing and inspecting the drive belt in your ATV. Learn everything you need to know to ensure the process is executed safely and efficiently to achieve optimal performance!

How to Change Drive Belt on Polaris Sportsman 500

To change the drive belt on a Polaris Sportsman 500, you must first prepare the vehicle, remove the seat and footwell, and then detach the PVT air outlet duct hose. Next, you must remove the clutch cover and, finally, the drive belt. Now you can install the new one.

But when should I replace my Polaris drive belt, and how long does it take to break in a Polaris belt? With proper maintenance, Polaris ATV belts may last 3,000 to 3,500 miles. However, if you encounter signs such as unusual noises emitted from the belt, shuttering engagement, or vibration during rides, it could indicate an earlier replacement is necessary.

Whether you need professional support, services, or advice, we are here to help. At Wickham Tractor, you can find the best Polaris equipment and parts to ensure your ATV is in top-notch condition. With that said, here are the steps for changing belt on Polaris Sportsman 500:

How to remove drive belt

Preparation

For the first step, you must prioritize safety and preparation. Ensure your Polaris is parked on a flat, level surface. Put the vehicle in park, and set the parking brake, to prevent any accidental movement during the procedure.

Next, wear protective gear to ensure safety while working on your ATV. Always use gloves and safety goggles to protect yourself from potential hazards. Finally, assemble all the required tools before beginning the procedure. This includes:

• Socket set
• Ratchets
• Torque wrench
• Multifunction pliers
• Shop rags

Seat and footwell removal

To remove the seat on your Polaris, lift the rear of the seat and pull back to detach it. Move to the left side of the ATV to remove the footwell. 

Then, use a multifunction plier to extract the four fasteners and nuts from the footwell’s bottom. Lastly, pivot the footwell away from the body panels to disengage the retaining tabs and completely remove it.

PVT air outlet duct hose

You first need to loosen the clamp on the PVT using a 6mm socket. Next, pull the bottom support out of the chassis to complete the removal.

Clutch cover removal

To remove the clutch cover from your Sportsman 500, begin by using a socket to take out the eight clutch cover fasteners keeping it in place. Then, carefully pull the cover out, pivoting the rear portion downward to detach it from the air duct hose. Once the cover is separated, pivot it completely off the vehicle.

After you’ve removed it, inspect the cover for any signs of damage or wear. You can replace the seal if necessary to ensure a proper fit and maintain the integrity of the clutch assembly.

Removing the drive belt

Several crucial steps ensure proper performance and maintenance when removing the drive belt from your Sportsman 500. First, squeeze the belt’s center to spread the clutch sheaves, easing removal. Carefully walk the belt off the drive clutch and remove it from the drive clutch. Note the belt’s rotation direction for proper reinstallation.

Next, inspect the belt for fraying, loose cords, missing cogs, hourglassing, abrasions, burns, or damage. After inspection, clean the inside of the clutch covers thoroughly and remove all debris and dirt around the PVT and the entire clutch air duct.

If you see any signs of oil leaks, it may be an indicator that debris could be trapped behind the clutches. Utilize a flashlight to inspect behind the clutches. This ensures thorough cleaning, which is essential for maintaining the peak performance and longevity of your ATV.

How to install a new drive belt

When replacing the belt, you must confirm that the part you install is correct for your ATV. The part number on the belt should face outward upon installation. A new belt for an EBS clutch should have part number 3211113, while the belt for a non-EBS clutch vehicle is part number 3211077.

Carefully loop the belt over the drive clutch and proceed to guide it over the driven clutch sheave. If the belt catches at the bottom of the seave, gently push down on it and continue the installation. Once in place, spin the driven clutch five to seven times to help seat the belt correctly within the clutch assembly.

Reassembling the vehicle

To assemble the vehicle, start by securing the clutch cover to the air duct hose, ensuring it is fully seated. Fasten the eight cover screws, securing the crankcase hose clip in the correct position. 

Next, reattach the footwell, align support with mounting holes, and secure the nuts. Finally, reinstall the seat, ensuring all components are properly aligned and secured.

Conclusion

Following our guide can help you successfully remove, inspect, and replace the drive belt on your ATV. Understanding each step on how to change drive belt on Polaris Sportsman 500 and completing the process with caution and precision will ensure that your vehicle maintains optimal performance and operation.

Remember to always prioritize safety and take necessary considerations and precautions to avoid injury or damage to your vehicle. If you need further guidance, refer to the manufacturer’s manual for specifications or contact our expert team!