2008 Sportsman 800 drive belt problems - Polaris ATV Forum
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post #1 of 6 (permalink) Old 07-10-2019, 01:44 PM Thread Starter
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2008 Sportsman 800 drive belt problems

My drive belt keeps blowing up about once a year. I’ve had it for 4 years and it has been consistently around 10-12 months after I change the belt that it just basically blows up and chunks of it are all over in the cover and the string wraps all around the clutch. I’m finally getting sick of having to buy a new belt and replace it so often and I want to get to the bottom of this issue. I thought it was the way I drive it but I’ve been using low gear a lot more when I should and it still goes bad so could something be wrong with the clutch and if so how would I go about fixing it?
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post #2 of 6 (permalink) Old 07-11-2019, 06:58 AM
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Tell us more!! You running bigger tires??? Lot of mud?? How many miles n hrs on the machine? You definitely have a problem!!!

2011 Sportsman® 800 EFI
GURU front brush guard
GURU rear brush guard
Polaris front lock n ride cargo box
Polaris rear rack extender
Warn RT 3.0 winch w/amsteel synthetic line
Viper aluminum haus fairlead
Polaris front spring adjusters
Ricochet a-arm guards
Ricochet full frame skid plate
ITP T-7 beadlock 14" w/OMF inner rim guards
Maxxis big horn 2.0 26x9 front
Maxxis big horn 2.0 26x11 rear
QSC clutch kit
EPI HD springs front n rear
ODI rogue 130mm grips
Ultraseal commercial grade tire sealant (front)
Highlifter tire sealant (rear)
CTEK 3300 battery maintainer
added 7 zerks
beefed up wiring harness
OGIO rear bag
ROTOPAX 1gal. + 2gal. gasoline can
Jccapri bushing kit
Kolpin Over Fenders
Rigid Industries E-Series 10" flood
Walker Evans struts
NGK Iridium's (2,500 miles on Champion's and they looked great!)
Odyssey Extreme battery PC545

2018 Sportsman® 570-T
2019 Aluma® A8818
2020 Outlander® 1000R XXC (on order, ETA mid-Sept)
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post #3 of 6 (permalink) Old 07-11-2019, 08:41 AM Thread Starter
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I think the tires are 22 inch. I have 3,972 miles and 315 hours on it. I don’t do too much mudding. I ride in open dirt fields a lot but not when they are too wet. It’s a lot of road and grass driving.
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post #4 of 6 (permalink) Old 07-11-2019, 12:32 PM
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Heat is usually what kills a belt and causes it to explode. Check that your air ducts are not obstructed and that clutch alignment is good. Misalignment and scrubbing on one side of the sheaves creates excess heat hardening the belt compound over time. The hardened belt will then crack leading to catastrophic failure at high speed.
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post #5 of 6 (permalink) Old 07-11-2019, 01:52 PM Thread Starter
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I will check the ducts and make sure that is all good. How would I go about checking the alignment myself?
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post #6 of 6 (permalink) Old 07-11-2019, 02:11 PM
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It sounds like your clutches need to be rebuilt!!!!

2011 Sportsman® 800 EFI
GURU front brush guard
GURU rear brush guard
Polaris front lock n ride cargo box
Polaris rear rack extender
Warn RT 3.0 winch w/amsteel synthetic line
Viper aluminum haus fairlead
Polaris front spring adjusters
Ricochet a-arm guards
Ricochet full frame skid plate
ITP T-7 beadlock 14" w/OMF inner rim guards
Maxxis big horn 2.0 26x9 front
Maxxis big horn 2.0 26x11 rear
QSC clutch kit
EPI HD springs front n rear
ODI rogue 130mm grips
Ultraseal commercial grade tire sealant (front)
Highlifter tire sealant (rear)
CTEK 3300 battery maintainer
added 7 zerks
beefed up wiring harness
OGIO rear bag
ROTOPAX 1gal. + 2gal. gasoline can
Jccapri bushing kit
Kolpin Over Fenders
Rigid Industries E-Series 10" flood
Walker Evans struts
NGK Iridium's (2,500 miles on Champion's and they looked great!)
Odyssey Extreme battery PC545

2018 Sportsman® 570-T
2019 Aluma® A8818
2020 Outlander® 1000R XXC (on order, ETA mid-Sept)
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