Snowmobile Polaris 550 IQ Shift / 550 IQ 136 / 550 IQ LXT (2013 year). Manual - part 20

82

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. 

NOTICE: 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 autho-
rized POLARIS dealer. Any unauthorized modifications to clutches, 
such as adding or removing weights, will void the warranty.

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.

83

MAINTENANCE

Clutch System

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 Drive Belt Troubleshooting on page 
107.

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

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.

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. Open the hood. 

5. Remove the left side panel.

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.

84

MAINTENANCE

Clutch System

Drive Belt Installation

1. Drop the drive belt over the 

drive clutch and pull back the 
slack. The belt cord line 
should be flush with, or 
slightly above, the outer cir-
cumference of the driven 
clutch sheaves. The belt will 
seat itself in the driven clutch 
during the break-in period. 
Adjust the belt ride-out after 
the break-in period by read-
justing belt deflection.

Tip: To ensure satisfactory belt life, install belts so they operate in the same 

direction of rotation by positioning the identification numbers so that you 
can read them.  If required, separate the sheaves as outlined in the belt 
removal procedures.

2. Rotate the L-wrench counter-clockwise to tighten the sheaves while 

working the belt to the outer edge of the sheaves.

3. Remove the L-wrench and store it in the tool kit.

4. Reinstall the side panel.

5. Close and secure the hood.

6. Break in the new belt. See page 49.

Drive Belt

Belt width and length must match the center distance of the clutches and 
sheave width of the drive clutch. POLARIS recommends the use of 
O.E.M. belts. Other belts may match the dimensions, but can drastically 
change the shift pattern, resulting in poor performance. 

Tip: A worn belt will continue to function, but will not deliver maximum perfor-

mance. Always carry a spare belt in case of an emergency.

85

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 inch 
(3.2 cm).

Drive Belt Adjustment

1. Install the L-wrench into the open threaded hole in the outer sheave 

of the clutch (see page 83). Turn the wrench clockwise slightly to 
remove pressure from the sheaves.

2. Loosen the 7/16-inch jam nut.

3. 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.

4. Tighten the jam nut. Store the L-wrench in the tool kit.

Torque Stop

Periodically check torque stop 
clearance. With clutches in 
proper alignment, the torque 
stop clearance should be .010-
.030 inch (.25-.75 mm) from 
the engine case.

Adjust if necessary, and lock 
the jam nut.

1

2

.010-.030 inch

 

(.25-.75 mm)