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RZR 4 Belt Change. Its as easy as 1,2,3!!

This is a discussion on RZR 4 Belt Change. Its as easy as 1,2,3!! within the RZR 4 Specific Discussion forums, part of the General RZR category; I smoked my belt pretty bad the last time I rode, so I decided to change it out. Having never changed a belt on a ...


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  #1  
Old April 27th, 2010, 04:44 PM
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RZR 4 Belt Change. Its as easy as 1,2,3!!

I smoked my belt pretty bad the last time I rode, so I decided to change it out. Having never changed a belt on a RZR at my house, I thought I'd at least try it & if I couldn't I'd take it to my shop. It took me more time to figure it out than it did to change it. I watched the video's on You Tube but the new 4 was nothing like the "S" or the std RZR I had b4.

Here's how I did it. It literally took about 15 minutes from time I started to putting it back together. It took a total of 6 tools 7 if you count rachet.

Tools required:
3/8" drive - 5/8" socket, 1/2" socket, 3/8" socket, long extension and rachet
Screwdriver, 5/8" wrench

REMOVAL of OLD BELT
1. Remove rear seats
2. Remove rear plastic engine cover
3. Remove rear seat cross member 2 bolts(uses a 5/8" socket and wrench)
4. Remove CVT out flow snorkle - there is 1 hose clamp (screwdriver needed here and 2 plastic clips)
5. Remove CVT cover - there are 8 or so small screws which uses 3/8" socket and this is where you'll need an extension at least 6"s, I actually used a 9".
6. Remove belt by pulling up on old belt, this will give you enough slack to ride the belt over the secondary pulley.
7. Remove secondary pulley using a 1/2" socket - NOTE - hold the secondary clutch w/your hand and slide off, it is alligned on splines. The entire secondary pulley including the spring comes off as 1 piece. (Mine came off very easy)

Installing NEW BELT
8. Slide new belt over primary and w/the secondary in your hand put the NEW belt on it.
9. Align the secondary on to the output shaft and then align the splines up and slide on.
10. Re-Install bolt into secondary pulley and torque according to specs.
11. Re-install CVT cover. There is a rubber type gasket in the CVT housing make sure this is installed. I also put a generous amt of axle grease on to seal it up from water.
12. Follow steps 1-7 in reverse order.

After re-stalling cover, i started the 4 up and took it for a test run around the yard. It worked like new again. Then I finished putting the seats back in.

Can be done in the field, using the steps I listed above. I saved my old belt, there weren't any missing teeth but it was glazed over.
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'11 Polaris Sportsman 850 orange XP w/EPS - 3" High lifter lift, 31" Laws, ATV Guru bumpers front and rear, KFI 3000# winch, HL 1.5" spacers, stealth snorkle and custom exhuast, Cajun dry box. (mine)
'10 RZR 4 - 3" CATVOS lift, 30" G. Sbacks, Maier scooped hood, headache net, Pol. Aluminum front bumper, Pol. rear bumper, Viper 4500# winch, 1" Super ATV spacers front/rear, Custom Snorkeled (hers)

Last edited by Bfree; April 27th, 2010 at 04:48 PM.
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  #2  
Old April 27th, 2010, 05:52 PM
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Re: RZR 4 Belt Change. Its as easy as 1,2,3!!

why did you remove the secondary?
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  #3  
Old April 27th, 2010, 06:35 PM
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Re: RZR 4 Belt Change. Its as easy as 1,2,3!!

The new belt would not go on w/out me removing the secondary. The Secondary is held on by one bolt and its an all one piece system. It doesn't come apart when you take it off.
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'11 Polaris Sportsman 850 orange XP w/EPS - 3" High lifter lift, 31" Laws, ATV Guru bumpers front and rear, KFI 3000# winch, HL 1.5" spacers, stealth snorkle and custom exhuast, Cajun dry box. (mine)
'10 RZR 4 - 3" CATVOS lift, 30" G. Sbacks, Maier scooped hood, headache net, Pol. Aluminum front bumper, Pol. rear bumper, Viper 4500# winch, 1" Super ATV spacers front/rear, Custom Snorkeled (hers)
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  #4  
Old April 27th, 2010, 06:42 PM
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Re: RZR 4 Belt Change. Its as easy as 1,2,3!!

ya I know... but you don't have to take it off if you don't want to.
try this:

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  #5  
Old April 27th, 2010, 06:44 PM
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Re: RZR 4 Belt Change. Its as easy as 1,2,3!!

I saw that video, but my RZR 4 is totally different. There is no way to put an extension on it. It doensn't have that part built in. Besides the new belt I put on was about 1" shorter than the OEM. Its a prototype Xtreme duty from Dayco. Maybe the OEM will roll on but this one would not. Believe me I tried. I looked at every aspect of your video (which is very helpful too) but not for me today.
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'11 Polaris Sportsman 850 orange XP w/EPS - 3" High lifter lift, 31" Laws, ATV Guru bumpers front and rear, KFI 3000# winch, HL 1.5" spacers, stealth snorkle and custom exhuast, Cajun dry box. (mine)
'10 RZR 4 - 3" CATVOS lift, 30" G. Sbacks, Maier scooped hood, headache net, Pol. Aluminum front bumper, Pol. rear bumper, Viper 4500# winch, 1" Super ATV spacers front/rear, Custom Snorkeled (hers)
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  #6  
Old April 27th, 2010, 06:47 PM
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Re: RZR 4 Belt Change. Its as easy as 1,2,3!!

it must have the rapid reaction secondary...
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  #7  
Old April 27th, 2010, 06:49 PM
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Re: RZR 4 Belt Change. Its as easy as 1,2,3!!

Yes, thats what it says on the outside of the Secondary Pulley. RAPID REACTION.
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'11 Polaris Sportsman 850 orange XP w/EPS - 3" High lifter lift, 31" Laws, ATV Guru bumpers front and rear, KFI 3000# winch, HL 1.5" spacers, stealth snorkle and custom exhuast, Cajun dry box. (mine)
'10 RZR 4 - 3" CATVOS lift, 30" G. Sbacks, Maier scooped hood, headache net, Pol. Aluminum front bumper, Pol. rear bumper, Viper 4500# winch, 1" Super ATV spacers front/rear, Custom Snorkeled (hers)
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Old April 27th, 2010, 06:57 PM
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Re: RZR 4 Belt Change. Its as easy as 1,2,3!!

So TUF, whats the diff b/tn the Rapid Reaction and the others out there that are on the RZRs? Is the Rapid Reaction better/worse? You seem to know to alot about this & Im trying to get educated.
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'11 Polaris Sportsman 850 orange XP w/EPS - 3" High lifter lift, 31" Laws, ATV Guru bumpers front and rear, KFI 3000# winch, HL 1.5" spacers, stealth snorkle and custom exhuast, Cajun dry box. (mine)
'10 RZR 4 - 3" CATVOS lift, 30" G. Sbacks, Maier scooped hood, headache net, Pol. Aluminum front bumper, Pol. rear bumper, Viper 4500# winch, 1" Super ATV spacers front/rear, Custom Snorkeled (hers)
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  #9  
Old April 27th, 2010, 07:47 PM
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Re: RZR 4 Belt Change. Its as easy as 1,2,3!!

Quote: Originally Posted by Bfree View Post
So TUF, whats the diff b/tn the Rapid Reaction and the others out there that are on the RZRs? Is the Rapid Reaction better/worse? You seem to know to alot about this & Im trying to get educated.
Some info around regarding the change:

http://www.rzrforums.net/engine-driv...ry-clutch.html
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Old April 27th, 2010, 07:54 PM
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Re: RZR 4 Belt Change. Its as easy as 1,2,3!!

the simple answer is that the rapid reaction costs less, so that is why Polaris uses it.
there are a lot less parts in the rapid reaction than the team roller.
the team roller has a helix you can take out and replace with a helix that has different angles...
for a stock engine the rapid reaction is OK, but you can't tune it as much as a team roller.
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  #11  
Old April 28th, 2010, 04:27 AM
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Re: RZR 4 Belt Change. Its as easy as 1,2,3!!

Makes sense now, Thanks for the info.
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'11 Polaris Sportsman 850 orange XP w/EPS - 3" High lifter lift, 31" Laws, ATV Guru bumpers front and rear, KFI 3000# winch, HL 1.5" spacers, stealth snorkle and custom exhuast, Cajun dry box. (mine)
'10 RZR 4 - 3" CATVOS lift, 30" G. Sbacks, Maier scooped hood, headache net, Pol. Aluminum front bumper, Pol. rear bumper, Viper 4500# winch, 1" Super ATV spacers front/rear, Custom Snorkeled (hers)
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Old April 28th, 2010, 05:30 AM
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Re: RZR 4 Belt Change. Its as easy as 1,2,3!!

Yep I changed mine very easy without taking off the secondary. But all this info is great for new guys.
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Old April 28th, 2010, 09:30 AM
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Re: RZR 4 Belt Change. Its as easy as 1,2,3!!

You dont have to take the secondary off...rapid reaction or not. Just grab the belt with your hands and pull/force it into the sheaves of the secondary...its not hard at all. Then roll it off, you can even roll it off without pushing it into the secondary, but that is hard work.

Having a Team secondary is nice since you can just use mechanical advantage to force it down like you see in Tuffs vid.
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Old April 28th, 2010, 09:43 AM
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Re: RZR 4 Belt Change. Its as easy as 1,2,3!!

It takes a lot of hand strength or a good back to use the belt to force the secondary sheaves apart. Maybe it would be much easier taking it off.
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Old April 28th, 2010, 09:55 AM
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Re: RZR 4 Belt Change. Its as easy as 1,2,3!!

Quote: Originally Posted by guy48065 View Post
It takes a lot of hand strength or a good back to use the belt to force the secondary sheaves apart. Maybe it would be much easier taking it off.
I guess...im not a weakling but im no hulk and I can do it with an upgraded secondary spring. You sort of roll the clutch as you pull on the top and bottom of the belt at the same time. Give it a chance...

You "can", and ive done it before, is take a wooden dowel with a rounded head and us it to tap the sheave open.
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