I have an '04 Rancher AT. Very reliable machine! But I want something with more power and load-carrying ability, so I'm going to be upgrading to a larger class (500 cc or more). While researching other machines, and there are many attractive options, I've found that all of the non-Honda options are belt-driven. I like the direct drive the Hondas use, but the King Quad and the Bombardier 800 look like outstanding ATVs. My question is this: How much more reliable is the direct drive over the belt-driven machines? I have a friend who has a belt-driven Kawi and he hasn't had any issues with it. I've noticed a few posts here and there that mention a broken belt, but they have been few and far between, so I get the impression belts don't break often, but Murphy's Law.... Also, if a belt breaks, would it leave you stuck in the boonies, or just affect the front wheels? Are the belts changable in the field?

 

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If youre looking for more towing ability, then make sure you find one with a low range. If you stick with the suzuki made trannys (on a/c or suzuki) or the yamaha made trannys, they are differnt from the kawi and polaris made trannys.
I cant remeber anyone ever breaking a yamaha belt,and left stranded.
You would need a few hand tools, to change a belt , and it helps to have things clean and stay clean. I suppose it could be done, but its highly unlikely a suzi or yami belt would ever break. And if you inspect it once a year, youll have plenty of time to catch a rare, bad belt before it breaks.
The reason the kawi and polaris belts are more likely to break is due to, them being wear items. They are the clutch in the belt drive system. When the motor goes to idle, the primary sheave opens and the belt goes slack. When the throttle is opened, and the rpms come up... the sheave then closes up, and the belt, because of friction, will start to spin. You can see now, why the kawi and polaris system needs to be in low, for slow going. The mechanical advantage of lower gearing , helps to minimize the burning and wear on the belt.
The yami and suzi belts never go slack, and are not wear items. Theres a separate clutch, which allows idleing in gear.
Not all belt cvts are the same, although most people think they are. The therory is the same, but the mechanical differences are signifigant.
If the belt on any cvt belt tranny breaks...yes you are stranded.