Polaris RZR XP Turbo Belt Replacement Guide
🔧 How to Replace the Drive Belt on a 2016–2021 Polaris RZR XP Turbo & XP 4 Turbo
Maintain peak performance on your Polaris RZR XP Turbo or XP 4 Turbo with our complete step-by-step guide to replacing the CVT drive belt. Whether you're dealing with belt slippage or planning routine maintenance, this tutorial helps ensure a smooth ride every time. 🏁
🧰 Required Tools & Supplies
- Shop Rags
- Safety Glasses 👓
- Nitrile Gloves 🧤
- Driven Clutch Spreader Tool
- 8mm and 1/4-Inch Sockets
- Ratchet 🔩
- Torque Wrench
🛠️ For more on tools and fasteners, check out our Tools & Fasteners Guide.
📋 Step-by-Step Drive Belt Replacement
- Park your RZR on a flat, level surface and place the transmission in PARK.
- Using a 1/4-inch socket, loosen the PVT duct clamp on the outer PVT cover.
- Remove the PVT intake duct and move it aside.
- Loosen and remove the nine outer clutch cover bolts with an 8mm socket.
- Gently maneuver the clutch cover out. Inspect the cover seal (part #5416207) and replace if worn.
- Note the current belt's rotation direction if you plan to reuse it.
- Insert the clutch spreader tool into the driven clutch's threaded hole. Turn clockwise to open the sheaves.
- Walk the belt off the driven clutch, then remove it from the drive clutch.
- Inspect the belt for wear: fraying, glazing, missing cogs, or damage.
- Clean the clutch housing thoroughly. ❗ Leaving debris may cause future damage or control loss.
- If replacing, ensure part number 3211202 is visible and facing outward.
- Loop the new belt over the drive clutch, then walk it onto the driven clutch.
- Remove the spreader tool and spin the driven clutch 5–7 times to seat the belt.
- Reinstall the clutch cover and ensure the seal is fully seated.
- Install all nine fasteners and torque to 35 in-lbs (4 Nm).
- Reinstall the PVT duct and torque the hose clamp to 35 in-lbs (4 Nm).
💡 Pro Tip: Always keep a spare drive belt in your RZR tool kit. It can be a ride-saver out on the trail!
