6.6
9924707 - 2013–2014 RZR 800 Service Manual
© Copyright 2013 Polaris Sales Inc.
Overheating / Diagnosis
During routine maintenance, or whenever PVT system overheating is evident, it’s important to check the inlet and
outlet ducting for obstructions. Obstructions to air flow through the ducts will significantly increase PVT system
operating temperatures. The vehicle should be operated in Low when plowing or pulling heavy loads, or if extended
low speed operation is anticipated.
CLUTCH DRIVE BELT & COVER RELATED ISSUES: DIAGNOSIS
Possible Causes Solutions / What to do
Loading the vehicle into a truck or tall trailer when
in high range.
Shift transmission to Low during loading of the vehicle to prevent belt burning.
Starting out going up a steep incline from a
stopped position.
When starting out on an incline, use Low gear. Shift transmission to Low during loading of
the vehicle to prevent belt burning.
Driving at low RPM or low ground speed (at
approximately 3-7 MPH).
Drive at higher speed or use Low. The use of Low is highly recommended for cooler PVT
operating temperatures and longer component life.
Insufficient engine warm-up when exposed to low
ambient temperatures.
Warm engine at least 5 min., then with transmission in neutral, advance throttle to approx. 1/
8 throttle in short bursts, 5 to 7 times. The belt will become more flexible and prevent belt
burning.
Slow and easy clutch engagement. Fast, effective use of the throttle for efficient engagement.
Towing/Pushing at low RPM or low ground speed. Use Low only.
Plowing snow, dirt, etc./utility use. Use Low only.
Stuck in mud or snow.
Shift the transmission to Low, carefully use fast, aggressive throttle application to engage
clutch. WARNING: Excessive throttle may cause loss of control and vehicle overturn.
Climbing over large objects from a stopped
position.
Shift the transmission to Low, carefully use fast, aggressive, brief throttle application to
engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle
overturn.
Belt slippage from water or snow ingestion into
the PVT system.
Shift the transmission to neutral. Using the throttle, vary the engine rpm from idle to full
throttle. Repeat several times as required. During this procedure, the throttle should not be
held at the full position for more than 10 seconds. Clutch seals should be inspected for
damage if repeated leaking occurs.
Clutch malfunction.
Clutch component inspection should be performed by a Polaris MSD certified technician.
Poor engine performance.
Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or faulty fuel pump may
cause symptoms similar to clutching malfunction.
GENERAL RANGE OPERATION GUIDELINES:
Low: Heavy pulling, basic operational speeds less than 7 MPH, riding through rough terrain
(swamps, mountains, ect.), or low ground speeds.
High: High ground speeds, or speeds above 7 MPH.
Operating in Low Gear
Low gear should be used when pulling heavy loads, riding through rough terrain, or when basic operational ground
speeds are less than 7 MPH. Use High gear when basic operational ground speeds are more than 7 MPH.
IMPORTANT: Using High gear for heavy loads, hilly terrain, or in wet, muddy conditions will increase the
chance of drive belt burning.
CLUTCHING
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