Ebs Driven Clutch Bushing Service - Polaris SPORTSMAN 400 2003 Service Manual

CLUTCH
EBS Drive Clutch Cover Bushing Removal
1. Install main adapter (Item 8) on puller.
Removal Tool (3)
Main Adapter
(8)
EBS Drive Clutch Cover Bushing Removal
2. Install adapter reducer (Item 9).
3. From outside of clutch cover, insert removal tool
(Item 3) into cover bushing.
4. With inside of cover toward vise, slide cover onto
puller.
5. Install nut onto puller rod and hand tighten. Turn
puller barrel to increase tension as needed.
6. Turn clutch cover counterclockwise on puller rod
until bushing is removed and cover comes free.
7. Remove nut from puller rod and set aside.
8. Remove bushing and bushing removal tool from
puller. Discard bushing.
EBS Drive Clutch Cover Bushing Installation
1. Apply Loctitet 609 evenly to bushing bore in
cover.
2. Working from inside of cover, insert new bushing
and bushing installation tool into center of clutch
cover.
3. With main adapter on puller, insert cover onto
puller rod, placing outside of cover toward vise.
4. Install nut on rod and hand tighten. Turn puller
barrel to apply more tension if needed.
5. Turn clutch cover counterclockwise on puller rod
until bushing is seated.
6. Remove nut from puller rod. Take installation tool
and clutch cover off rod.
6.30
EBS DRIVEN BUSHING
SERVICE
EBS Driven - Bushing Removal
Nut (C)
1. Install puller adapter (Item 10) onto puller.
Adapter
Reducer (9)
Piston Pin
Puller
2. Insert EBS main adapter (Item D) onto puller. See
3. Install bushing removal tool (Item E) into center of
4. Install sheave onto puller.
5. Install left hand nut onto puller rod and tighten by
6. Using a hand held propane torch, apply heat
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
Ill. 1
Ill. 1.
clutch sheave. See Ill. 2.
Bushing
Removal Tool (E)
Ill. 2
hand. Turn puller barrel for further tension if
needed.
evenly around outside of bushing until tiny smoke
tailings appear.
bushing is removed and sheave comes free.
D