How to Replace the Drive Belt on a Polaris RZR 900S

Replacing the drive belt on a Polaris RZR 900S requires only the most basic tools, and about 20 minutes of your time. 

Watch the video above and follow the step-by-step walkthrough below to learn how to replace the drive belt on a Polaris RZR 900S, and how to clean both the primary and secondary clutch while you're at it. 

NOTE: The Polaris RZR 900S' primary clutch is commonly called the drive clutch, and the secondary clutch is commonly called the driven clutch. We use those terms in this guide.

Tools and Parts Needed - Polaris RZR 900 Drive Belt Change

Tools

  • Ratchet and extensions
  • 8mm, 15mm sockets
  • 10mm wrench
  • Torque wrench

Parts

Removing and Inspecting Polaris RZR 900S Drive Belt

Step 1. Remove the left side rear wheel. 

PRO TIP: It's not strictly necessary to remove the wheel, but it makes the job much easier without it in the way.

Polaris RZR 900S drive belt change

Step 2. Remove the grease zerk from the top of the upper A-arm where it meets the chassis. 

Polaris RZR zerk fitting removal

Step 3. Remove the outer clutch cover, and inspect the rubber seal that sits between the outer and inner clutch covers. If the seal looks worn, or if there are signs that water has been getting into the clutch covers, replace the clutch cover seal

Polaris RZR outer clutch cover removal

Step 4. Remove the drive belt by loosening the driven clutch center bolt to allow some play in the driven clutch wheel, then slip the drive belt off the clutch wheel.

Polaris RZR 900 drive belt removal

PRO TIP: If you're going to reinstall the old drive belt, note which direction the printing on it faces and reinstall it the same way.

Step 5. Inspect the drive belt for any cracks or broken teeth on the inside and outside of the belt. Replace the drive belt if necessary.

Polaris RZR 900 drive belt inspection

Cleaning Polaris RZR 900S Driven and Drive Clutches

Step 1. Remove the center bolt, pull the driven clutch out from the inner clutch cover, and separate the two halves of the driven clutch.

Polaris RZR driven clutch removal

Step 2. Inspect the inner drive surfaces (sheaves) of the driven clutch to make sure they haven't glazed over. Clean and lightly scuff the sheaves with a nylon pad and brake/contact cleaner.

Polaris RZR driven clutch sheave inspection

Step 3. Put the two halves of the driven clutch back together, making sure the X-marks on both halves are aligned. Reinstall the driven clutch onto the inner clutch cover.

Polaris RZR 900 driven clutch assembly

Step 4. Leave the drive clutch in place, and reach in to check that its central bearing is rotating freely. Next, clean the drive clutch's sheaves, again using a nylon pad and brake/contact cleaner.

Polaris RZR 900 drive clutch cleaning

Replacing Polaris RZR 900S Drive Belt

Step 1. Put a new drive belt (or reinstall the old drive belt if it's not too worn) over the drive clutch, and slip it back over the driven clutch.

Polaris RZR 900 drive belt installation

Step 2. Reinstall the driven clutch bolt and tighten it. Make sure you hold the drive belt out to the edges of the driven clutch as you tighten the center bolt to prevent the belt from getting pinched between the sheaves.

Polaris RZR 900S drive belt replacement

Step 3. If you're replacing the clutch cover seal, install the new one now. Make sure the white line on the new seal is facing toward the inside of the clutch cover, and be careful not to twist the seal.

Polaris RZR 900 clutch cover seal installation

Step 4. Reinstall the outer clutch cover, being careful not to overtighten the bolts as they can easily strip the plastic screw threads of the inner and outer clutch covers.

Polaris RZR 900 outer clutch cover installation

Step 5. Reinstall the grease zerk into the upper A-arm, followed by the rear wheel and you're done.

Polaris RZR 900 S drive belt change

BELT, DRIVE
Polaris

BELT, DRIVE

Qty.
SEAL, OUTER
Polaris

SEAL, OUTER

Qty.

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