How to Replace a Polaris RZR 900 Drive Belt
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 steps 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 - Polaris RZR 900 Drive Belt Change
- Ratchet and extensions
- 8mm, 15mm sockets
- 10mm wrench
- Torque wrench
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.
Step 2. Remove the grease zerk from the top of the upper A-arm where it meets the chassis.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
Step 5. Reinstall the grease zerk into the upper A-arm, followed by the rear wheel and you're done.