Snowmobile Polaris 600 Switchback / 800 Switchback (2013 year). Manual - part 25

100

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. 

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 snowmobile 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.

NOTICE: The bushings in the weights and rollers of POLARIS clutches are 

made of a material that may be damaged if lubricated. Do not lubri-
cate clutch bushings.

Clutch Alignment Offset

Clutch alignment offset is important for maintaining optimum perfor-
mance. See your dealer for service and adjustments. A special tool is 
required to check for proper alignment.

101

MAINTENANCE

Clutch System

Drive Belt Condition

Periodically check the condition and tension of the drive belt. 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 Drive Belt Troubleshooting on page 121.

Always carry a spare drive 
belt. Store the spare belt in 
the belt clip located under 
the left side of the hood. 
Make sure the o-ring is 
installed over the belt clip.

For improved drive-away during extremely cold temperatures, remove 
the belt and warm it to room temperature. Reinstall it before starting the 
snowmobile.

O-Ring

102

MAINTENANCE

Clutch System

Drive Belt Deflection

Measure belt deflection with both 
clutches at rest and in their full 
neutral position.

Place a straight edge (1) on the 
belt and apply downward pressure 
while measuring at point 2. This 
measurement should be 1 1/4 
inches (3.2 cm).

Drive Belt Adjustment

1. Loosen the 7/16-inch jam nut on the belt width adjuster.

2. Using a 1/8-inch Allen wrench, turn the set screw inward (clock-

wise) to increase the distance between the sheaves or outward 
(counter-clockwise) to decrease the distance.

3. Tighten the jam nut.

1

2

103

MAINTENANCE

Clutch System

Drive Belt Removal 

NOTICE: Do not attempt to remove the drive belt after operating in reverse. The 

snowmobile must be stopped after forward motion to prevent damage 
to components during belt removal. Rotate the driven clutch counter-
clockwise 1/4 turn by hand to ensure forward engagement before 
attempting to remove the belt.

1. Stop the engine after operating in a forward motion.

2. Turn the ignition key off. Wait for the engine to come to a complete 

stop.

3. Lock the parking brake.

4. Remove the left side panel.

5. Rotate the driven clutch counter-clockwise 1/4 turn by hand to 

ensure forward engagement.

6. Locate the L-wrench in the tool kit. Install the wrench into the open 

threaded hole in the outer sheave of the clutch.

7. Turn the wrench clockwise until the sheaves open far enough to 

remove the belt. If the wrench does not turn readily, rotate the 
driven clutch counter-clockwise an additional 1/4 turn by hand and 
try again.

8. Firmly grasp the belt midway between the clutches and pull upward 

and rearward to remove it.