Bushing Service; Moveable Sheave - Bushing Removal; Moveable Sheave - Bushing Installation - Polaris Ranger 500 2x4 2007 Service Manual

CLUTCHING

Bushing Service

*Clutch Bushing Replacement Tool Kit (PN 2871226)
#2
#8
Stamp Qty. Part Description
P-90 Drive/Driven Clutch
#2 1
Bushing Install Tool
Drive Clutch Cover
Bushing Removal/
#3 1
Installation Tool (all
clutches)
P-90 Driven Clutch Cover
#5 1
Bushing Removal Tool
#8 1 Main Puller Adapter
#9 1 Adapter Reducer
Number Two Puller
#10 1
Adapter

Moveable Sheave - Bushing Removal

1. Install handle end of the Piston Pin Puller (PN 2870386)
securely into bench vise and lightly grease puller threads.
Piston Pin Puller (PN 2870386)
2. Remove nut from puller rod and set aside.
3. Install the Main Puller Adapter (#8) (PN 5020632) onto the
Piston Pin Puller (PN 2870386).
Piston Pin Puller
(PN 2870386)
6.16
#3
#5
#9
#10
Part #
5020628
5020629
5020631
5020632
5010279
5020633
Main Puller Adaptor (#8)
(PN 5020632)
4. Insert the Number Two Adapter (#10) (PN 5020633) into
the bushing from belt side as shown. With towers pointing
toward vise, slide sheave and bushing onto puller rod.
5. Install the nut removed in Step 2 onto end of puller rod and
hand tighten. Turn puller barrel to increase tension on
sheave if needed. Nut is left hand thread
6. Turn sheave and puller barrel together counterclockwise on
puller rod until bushing is removed.
7. Remove nut from puller rod and set aside.
8. Pull bushing removal tool and adapter from puller rod.
Remove bushing from tool and discard.

Moveable Sheave - Bushing Installation

1. Place the Main Puller Adapter (#8) (PN 5020632) onto the
puller.
2. Apply Loctite™ 680 (PN 2870584) to the back side of new
bushing. Push bushing into center of sheave on tower side
by hand.
Bushing (PN 3576504)
Loctite 680 (PN 2870584)
™
3. Insert the Clutch Bushing Installation Tool (#2) (PN
5020628) into center of sheave and with towers pointing
away from vise, slide sheave onto puller rod.
#10