Polaris razors are the ultimate side-by-side recreational vehicles since they are lighter, smaller, and faster. However, the most frustrating aspect of these vehicles is their tendency to break belts, mainly when used off-road. What causes these belt breaks?
Your Polaris RZR keeps breaking belts due to spin burns, hourglassing, tight belts, or debris. Spin burns are the primary reason why Polaris RZRs break belts. These happen when the clutch overheats from too much slipping and seizing up, leading to belt breakage.
In the rest of this article, I’ll discuss why your Polaris RZR keeps breaking belts. I’ll also discuss some remedies to this problem.
Reasons a Polaris Razor Breaks Belts
Belts are an essential component in the operation of Polaris RZRs. These belts are located in the clutch system and are responsible for transferring power from the engine to the drivetrain (source).
Here are some reasons why a Polaris RZR belt breaks.
Spin Burns
The most common reason for belt breakage is spin burns. These occur when the clutch overheats from too much slipping and seizing up, causing the belt to break.
Clutch slipping and seizing happens when the Polaris RZR is used off-road, and the rider engages the throttle while going up a hill or over rough terrain. The constant slipping causes the clutch to overheat and eventually seize up, breaking the belt.
Using high gears to dislodge tires from sand and mud is another cause of spin burns. When you engage high gears to dislodge tires from mud and sand, the clutch will overheat, and the belt will break.
Hourglassing
Hourglassing happens when the belt wears in a V-shape due to misalignment or overloading of the vehicle. This weakens the belt and causes it to snap eventually.
Hourglassing in Polaris RZRs results from using high gears when loading and unloading. It can also be caused by overloading the vehicle or towing a heavy trailer. Such activities strain the belt, causing it to wear in a V-shape.
Tight Belts
When the belt is too tight, it stresses the clutch system unnecessarily, causing it to fail. This usually happens when the belt is incorrectly installed, or the spring tensioner is not appropriately adjusted.
A tight Polaris RZR belt will stretch beyond its elastic limit and eventually break (source). Thus, it’s essential to check the belt’s tension regularly and adjust it accordingly.
Debris
Debris can cause the belt to wear out prematurely or even break. Small stones, mud, and sand can get trapped between the pulleys and rollers, causing the belt to wear out prematurely.
Large objects can sometimes get caught in the belt, causing it to break. This usually happens when the vehicle is driven in an area with a lot of debris, such as a construction site.
How To Prevent Belt Breakage In Your Polaris RZR
A Broken belt in a Polaris RZR means you can’t do anything with the vehicle until after replacing it. So here are some ways to prevent the constant belt breakages on your side-by-side.
Use Lower Gears When Going Uphill or Over Rough Terrains
Going uphill or riding over rough terrains involves using a lot of force. In most cases, you’ll ride at speeds less than 10mph (4.47m/s). Using high gears in such conditions increases the chances of slipping the belt and causing spin burns, so you should use lower gears instead.
Here is a video that demonstrates when to use low and high gears:
Avoid Overloading Your Vehicle
Your vehicle is not meant to be overloaded with people or cargo. When you overload the vehicle, you put unnecessary stress on the belt, which can cause it to break.
It’s best to keep the weight within the recommended limit. You should consider using a trailer if you’re going to carry many people or cargo.
Keep Your Vehicle Free of Debris
You should be mindful of the terrain conditions when driving the vehicle. Avoid driving in areas with a lot of debris, such as construction sites.
If you must drive in such an area, inspect your vehicle afterward. Look for any debris that might have been caught in the belt and remove it to prevent premature wear or breakage.
Inspect and Replace the Belt When Necessary
As the belts rotate on the pulleys, they’ll eventually wear out. This is why it’s crucial to inspect the belt regularly and replace it when necessary.
You should also inspect the pulleys and rollers for any damage. If any of them are damaged, they can cause the belt to break prematurely.
Here is the procedure to inspect and replace your Polaris RZR belt:
- Park the vehicle on a flat and level surface.
- Loosen the lower and upper PVT hose clamps on the outer PVT cover.
- Loosen the exterior clutch cover fasteners.
- Remove the clutch cover.
- Inspect and replace the cover seal if necessary.
- Note the travel direction on the drive belt.
- Spread the sheaves by threading the clutch spreader tool into the driven clutch.
- Remove the belt from the clutch.
- Inspect the belt for spin burns, fraying, abrasions, loose cords, and hourglassing.
- Replace the belt if necessary.
- Clean the interior parts of the clutch cover.
- Remove any debris when replacing the drive belt.
- Re-install the belt in the same travel direction you noted before removing it.
- Loop the belt over the clutch and walk it over the clutch sheave.
- Install the outer clutch cover.
- Re-install the PVT duct.
Here is a video demonstrating how to inspect and replace belts on a Polaris RZR vehicle:
I recommend the SuperATV Heavy Duty Drive Belt (link to Amazon) for replacing your drive belt. This belt is built with trail-proven strength for durability and high torque.
If your speedometer isn’t working, there are some easy ways to fix it yourself. Read my guide to learn how.
Conclusion
The Polaris RZR is a great off-road vehicle, but it’s not without its flaws. One of the most common issues is belt breakage. This can be caused by several factors, such as going up hills or over rough terrain, towing a heavy trailer, or driving in an area with a lot of debris.
You can prevent belt breakages by using lower gears when going up hills or over rough terrain, avoiding towing a heavy trailer, and keeping your vehicle free of debris.