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!

How to Clean Your ATV and the Products We Use

Washing your ATV or UTV and choosing a product can be overwhelming with the selection at retail stores.  Generally we've found that you get what you pay for in this category.  We've tried lots of products and have found a combination of cleaning products that not only make the job easier, but also produce professional results.  This article will show you how to clean and wash you're ATV.
Now remember we are not affiliated with the companies that produce these products, but when we find things that work we pass it along.  Watch the process here. 
1. De-greaser: Auto Magic Red Hot (#51)
2. Wash: Auto Magic Wash and Wax (#56)
3. Shine: Auto Magic Magic Dressing (#33)  
4. Aluminum Cleaner: Purple Power Aluminum Brightener 

Doing this process will result in a professional detailed look for your ATV and should be done at least once a year to ensure it maintains top value.  Begin by gathering up the cleaning products and remember your first deep cleaning will be the hardest and those after will become easier.  Begin by knocking all the mud off the plastics and under the fenders.  Use a fanning motion with the pressure washer at at least a foot distance from the atv to ensure no decals are removed and water doesn't penetrate seals.  This is a good time to remove any front plastic that impedes a direct spray flush of the radiator.  Once all debris is off or loosened spray the entire quad down with degreaser and just before it dries wash it off.  Depending on the condition of your ATV this may have to be done twice.  Next support the ATV on jack stands and remove the tires and wheels.  Again, knock any dirt off the areas where gunk may have collected over the years.  Next pick an area with aluminum (motor, hubs, brake calibers, front or rear diff and apply the Aluminum Cleaner.  Let it sit for 10-15 seconds and wash off, if its left on to long it will dull the aluminum.  This may have to be done two to three times to get the premium results.  Once all aluminum has been cleaned.  Wash and scrub the entire ATV with the Wash and Wax, this step will keep fish eyes from developing while the ATV dries and the wax in the wash is a great conditioner for the powder coated frame.  Let your ATV dry in the sun or speed the process up by blowing off with a leaf blower.  To complete the process put your ATV in the sun and the plastics will warm up making them accept the dressing much better.  Spray Magic Dressing over the entire ATV very liberally and let it bake in the sun for couple hours.  Take a rag and remove any pooling or excessive dressing and you're done!

Sportsman 800 Front Gearcase Differential Fluid Change

Changing the front differential gearcase fluid on a 2012 Polaris Sportsman is not a hard job.  There is much debate about fluid compatibility, using the recommended Polaris Demand Drive Fluid or Angle Drive Fluid.  The Angle Drive Fluid is a thicker oil and is used in approximately 2004 and earlier Polaris models that engage the AWD at the front hubs.  These models have a larger bolt on center cap on the front wheels.  In the newer models the AWD system is referred to as being centralized and engages in the front differential gearcase and uses the thinner Demand Drive Fluid.  See the Difference between Demand Drive Fluid and Angle Drive Fluid here. We recommend sticking with the factory recommended Demand Drive Fluid.  
To watch the entire fluid change click here.

Before getting started have the following ready:
1. Polaris Demand Drive Fluid (9oz.)
2. 8mm allen wrench
3. oil catch pan
4. rags

Begin by driving the Sportsman 800 for a couple miles at road speeds to warm the fluid. Next park on level ground and removing the 8mm allen head drain plug located under the front skid plate.  The drain plug is magnetic, check for debris and remember some build up is normal.  While the fluid is draining remove the 8mm allen head fill plug located on front of the differential gearcase.  Re-install the drain plug and fill the gearcase with Demand Drive Fluid, approximately 9 oz. or until it reaches the bottom of the fill plug.