2005 Polaris Sportsman 400/500 Service Manual, Page 166Get this manual
CLUTCHING 4Measure belt width and replace if wornGenerally, belts should be replaced if clutches can no longer be adjusted to provide proper belt deflectionS The top edges have been trimmed on some drive beltsIt will be necessary to project the side profiles and measure from corner to cornerS Place straight edge on each side of the drive beltS Place another straight edge on top of beltS Measure the distance where the side straight edges intersect the top, as shown in the illustrationdeflection is the desired goalnot specific center distance8Replace belt if worn past the service limitBelts with thin spots, burn marks, etc should be replaced to eliminate noise, vibration, or erratic PVT operationSee Troubleshooting Chart at the end of this chapter for possible causes
Center Distance Projected Belt Width Clutch Center Distance 10 +.1-.05 (254 +2.5-1.3mm) Belt Nominal Length40.875 316 (103.8 cm .48 cm)