2001 Polaris Sportsman 400-500 DUSE and H.O. Service Manual, Page 203Get this manual
DRIVE BELT REMOVALINSPECTION
1Remove outer PVT cover as described in PVT Disassembly2Mark drive belt direction of rotation so that it can be installed in the same directionNOTE: Normally positioned so part numbers are easily read3To remove drive belt, apply brake, pull upward and rearward on belt to open driven clutch sheaves, pull out and down on belt to slip over the driven clutch outer sheave
4Measure belt width and replace if worn severelyGenerally, belt should be replaced if clutches can no longer be adjusted to provide proper belt deflection& The top edges have been trimmed on some drive beltsIt will be necessary to project the side profiles and measure from corner to corner& Place straight edge on each side of the drive belt& Place another straight edge on top of belt& Measure the distance where the side straight edges intersect the top, as shown in the illustration at right5Inspect belt for loose cords, missing cogs, cracks, abrasions, thin spots, or excessive wearReplace if necessary6Inspect belt for hour glassing (extreme circular wear in at least one spot and on both sides of the belt)Hour glassing occurs when the drive train does not move and the drive clutch engages the beltBelt Width: New 1.1741.188 (2.98-3.02 cm) Wear Limit 1.125 (2.86 cm)