Polaris Sportsman 850 Service Manual page 225

5. Install main adapter (D) onto puller.
6. With towers pointing toward the vise, slide sheave
onto puller rod.
7. Install bushing removal tool into center of sheave with
small side toward sheave.
NOTE
Bushing Tool:
PA-47336
8. Install nut (C) onto end of puller rod and hand tighten.
Turn puller barrel to increase tension on sheave if
needed. Using a hand held propane torch, apply heat
around outside of bushing until tiny smoke tailings
appear.
9. Turn sheave counterclockwise on puller rod until it
comes free. Lift sheave off puller.
10. Remove nut from puller rod and set aside.
11. Pull bushing removal tool and adapter from puller rod.
Remove bushing from tool and discard.
Moveable Sheave - Bushing Installation
12. Apply Loctite® 648 evenly to bushing bore inside
moveable sheave.
13. Set bushing in place on sheave.
14. Insert bushing tool (PA-47336) with small side down,
into center of bushing.
15. With towers pointing upward, slide sheave, bushing
and tool onto puller rod.
16. Install nut on puller rod and hand tighten. Turn barrel
to apply additional tension if needed.
17. Turn sheave counterclockwise, making sure bushing
is drawn straight into bore. Continue until bushing is
seated.
18. Remove nut from puller rod and set aside.
19. Remove sheave from puller.
20. Remove installation tool.
Cover Bushing Removal
21. Install main adapter (8) on puller.
22. Install adapter reducer (9).
23. From outside of clutch cover, insert removal tool (3)
into cover bushing.
24. With inside of cover toward vise, slide cover onto
puller. With inside of cover toward vise, slide cover
onto puller.
25. Install nut onto puller rod and hand tighten. Turn
puller barrel to increase tension as needed.
26. Turn clutch cover counterclockwise on puller rod until
bushing is removed and cover comes free.
27. Remove nut from puller rod and set aside.
28. Remove bushing and bushing removal tool from
puller. Discard bushing.
Cover Bushing Installation
29. Apply Loctite® 648 evenly to bushing bore in cover.
30. Working from inside of cover, insert new bushing and
bushing installation tool into center of clutch cover.
31. With main adapter on puller, insert cover onto puller
rod, placing outside of cover toward vise.
32. Install nut on rod and hand tighten. Turn puller barrel
to apply more tension if needed.
33. Turn clutch cover counterclockwise on puller rod until
bushing is seated.
34. Remove nut from puller rod. Take installation tool and
clutch cover off rod.
PVT SYSTEM
5
5.21