Polaris 2005 SPORTSMAN 500 Servise Manual page 184

CLUTCHING
EBS DRIVEN BUSHING
SERVICE
EBS Driven - Bushing Removal
1. Install puller adapter (Item 10) onto puller.
Ill. 1
2. Insert EBS main adapter (Item D) onto puller. See
Ill. 1.
3. Install bushing removal tool (Item E) into center of
clutch sheave. See Ill. 2.
Bushing
Removal Tool (E)
Ill. 2
4. Install sheave onto puller.
5. Install left hand nut onto puller rod and tighten by
hand. Turn puller barrel for further tension if
needed.
6. Using a hand held propane torch, apply heat
evenly around outside of bushing until tiny smoke
tailings appear.
CAUTION: Clutch components will be hot! In
order to avoid serious burns, wear insulated
gloves during the removal process.
7. Turn clutch sheave counterclockwise until
bushing is removed and sheave comes free.
6.32
8. Remove nut (C) (left hand thread) from puller rod
and set aside.
9. Remove adapters from puller.
10. Remove bushing and removal tool from adapters.
Discard bushing.
EBS Driven - Bushing Installation
1. Slide adapter (Item 10) onto puller.
EBS Driven Clutch Bushing Installation
Puller Tool (A/B)
Side "B" toward
D
sheave
Bushing
2. Apply Loctitet 609 evenly to bushing bore inside
moveable sheave.
3. Install sheave onto puller (belt surface up).
4. Place new bushing on side B of installation tool
(Item A/B) and slide both over puller rod.
5. Install nut (C) onto puller rod and hand tighten
against installation tool.
6. Turn clutch sheave counterclockwise until
bushing is seated.
7. Remove nut (C) (left hand thread) from puller rod
and set aside.
8. Remove installation tool and clutch sheave from
puller.
EBS Driven - Backside (Outer) Bushing Removal
1. Install main puller adapter (Item 8) onto puller.
2. Install adapter reducer (Item 9).
3. Using a hand held propane torch, apply heat
around outside of bushing until tiny smoke tailings
appear.
CAUTION: Clutch components will be hot! In
order to avoid serious burns, wear insulated
gloves during the removal process.
4. Flip sheave over onto puller.
5. Install bushing tool (Item 2).
6. Install left hand nut (C) and spacer onto puller rod
and tighten by hand. Turn puller barrel for further
tension if needed.
Nut (C)
Puller Adapter (10)