Polaris Sportsman 800 BELT CHANGE

The Sportsman 800 throws power to the ground through a CVT Belt setup.  Replacing the belt on the Sportsman is part of routine maintenance and belts do wear out over time.  If your belt is squealing or you notice a loss in performance it's probably time for a belt change.   Recently we had the opportunity take a look at the CVT or PVT (Polaris Variable Transmission) setup and change the belt on a 2012 Sportsman 800.  In this article we'll explain how to change the belt, but first here is what tools you'll need.    WATCH HOW TO VIDEO

1. To remove foot well: T25 Torx Bit, 10mm wrench
2. To remove belt cover: 10mm socket, extension, ratchet
3. To remove belt: 16mm socket, impact wrench, primary clutch puller

Begin by removing the foot well, secured by four T25 Torx screws and four plastic rivets.  You may have to pull upward slightly on the front and rear fender to completely release it.  Next you'll need to remove two plastic rivets located under the seat (see picture or watch video).  Removing these two plastic rivets will allow you to pull the plastic up and access the two clamps securing the rubber boot.  After loosening the clamps remove the eight 10mm bolts securing the PVT belt cover.  Next work the cover off by pulling outward and wiggling it at the same time.  Now that the cover is off you can see the PVT setup consisting of the primary clutch, secondary clutch and belt.  The primary clutch will need to be removed to gain enough slack to remove the belt.  There are other methods for removing the belt, but we have found this one to work best for us.  Next remove the 16mm bolt securing the primary clutch, it is standard threads, so counter clockwise removes it.  Next screw the primary clutch puller into the center of the primary clutch and tighten with a impact wrench.  It should pop off rather easily using this method.  Now that the primary clutch has been pulled remove the belt and take notice of the orientation.  Next reinstall the new belt and primary clutch.  Once the 16mm bolt has been reinstalled and tightened check the PVT belt cover seal.  The PVT cover seal needs to be removed and cleaned if dirty to ensure a water tight seal.  Once completed everything can be reassembled!