Snowmobile Polaris 550 Transport Trail Touring. Manual - part 23

90

MAINTENANCE

Lights

NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin 

leaves a residue, causing a hot spot that will shorten the life of 

the lamp. If fingers do touch the bulb, clean it with an alcohol-

moistened towel.

Headlight Bulb Replacement

1. Pinch the ends of the spring (1) 

together and lift until it releases 

from the spring retainer.

2. Lift the spring carefully around 

the wire harness (2) and flip it to 

the outside of the housing.

3. With the wire harness attached 

to the bulb (3), withdraw the 

bulb from the housing.

4. Grasp the bulb by its metal base 

and carefully separate the bulb from the harness.

5. Hold the new bulb by its metal base and install it into the wire har-

ness.

6. Insert the bulb into the housing. Carefully flip the spring back into 

the housing, placing it around the wire harness.

7. Squeeze the spring together until it's over the spring retainer and 

release.

8. Verify headlight aim. See page 89.

Taillight/Brakelight Replacement

1. Remove the screws (1) securing the 

taillight housing (2).

2. Remove and replace the bulb (3).
3. Reassemble all components.

1

2

3

1

2

3

91

MAINTENANCE

Clutch System

Periodically inspect clutch sheaves for damage, wear or belt residue. To 

maintain optimum performance, clean with non-oil based cleaners such 

as isopropyl alcohol. 

Clutch Alignment Offset

Clutch alignment offset is important for maintaining optimum perfor-

mance. Please see your Polaris dealer if you experience a decrease in 

performance.

Clutch Center Distance

See your Owner's Manual Supplement for recommended center distance 

for your machine. If adjustment is necessary, see your dealer.

n

Drive Belt Condition

Periodically check the condition and tension of the drive belt, and 

always carry a spare. Inspect the belt for signs of excessive wear: frayed 

edges, missing cogs, cracks and excessive looseness. Replace the belt if 

any of these conditions exist. See Belt Troubleshooting on page 118.

For improved drive-away during extremely cold temperatures, remove 

the belt and warm it to room temperature. Reinstall it before starting the 

snowmobile.

WARNING

If you become aware of higher than normal clutch engagement or an unusual 

vibration or shift pattern, see your dealer immediately. Do not operate the 

machine until repairs have been made. 
All clutch maintenance and repairs must be performed by an authorized 

Polaris dealer. Any unauthorized modifications to clutches, such as adding or 

removing weights, will void the warranty.

CAUTION

The bushings in the weights and rollers of Polaris clutches are made of a 

material that may be damaged if lubricated. Do not lubricate clutch bushings.

92

MAINTENANCE

Clutch System

Drive Belt Removal

1. Stop the engine after operating in a forward motion.
2. Turn the ignition key off. Wait for the engine to stop completely.
3. Lock the parking brake (if equipped).
4. Open the hood. 
5. Remove the clutch guard retain-

ing pin and open the clutch 

guard.

6. Locate the L-wrench in the tool 

kit and install it into the open 

threaded hole in the outer sheave 

of the clutch. Rotate the wrench 

until the sheaves open far enough 

to remove the belt.

7. Firmly grasp the belt midway 

between the clutches and pull 

upward and rearward to remove. 

See illustration.

CAUTION

Do not attempt to remove the drive belt after operating in reverse. The snow-

mobile must be stopped after forward motion to prevent damage to compo-

nents during belt removal.

93

MAINTENANCE

Clutch System

Drive Belt Installation

1. Drop the drive belt over the 

drive clutch and pull back 

the slack.

NOTE: To ensure satisfactory 

belt life, install belts so 

they operate in the 

same direction of rota-

tion by positioning the 

identification numbers 

so that you can read 

them. If required, sepa-

rate the sheaves as 

outlined in the belt removal procedures.

2. Turn the driven clutch moveable sheave clockwise while pushing 

inward and forcing the belt down between the sheaves.

3. Hold the belt down between 

the sheaves and roll the bot-

tom portion over the outer 

clutch sheave. Work the belt 

to the outer edge of the 

sheave.

4. Rotate the L-wrench to 

tighten the sheaves. Remove 

the wrench and store in the 

tool kit.

5. Close the clutch guard and 

reinstall the retaining pin.

6. Close and secure the hood and release the parking brake.