Polaris Sportsman 400 Service Manual page 226

CLUTCH
BUSHING REPLACEMENT, EBS DRIVE
EBS CLUTCH BUSHING REMOVAL AND INSTALLATION
Use Tool Kit PN 2201379
The contents of this kit include:
Item Qty. Part Description
A/B 1 EBS Drive Clutch and Driven Clutch
Puller Tool
C 1 EBS Drive Clutch and Driven Clutch
Puller Nut
D 1 EBS Main Adapter
E 1 EBS Bushing Removal Tool
1 Instruction
Also required:
Clutch Bushing Removal/Installation Tool Kit PN 2871226 (ATV Clutch Kit) or 2871025 (For all clutches)
Piston pin puller (PN 2870386)
REMOVAL AND INSTALLATION INSTRUCTIONS
NOTE: Bushings are installed at the factory using Loctitet 609. In order to remove bushings it will be necessary
to apply heat evenly to the area around each bushing. Clean all residual Loctite from bushing bore prior to instal-
ling new bushing.
EBS Drive Clutch Moveable Sheave - Bushing Removal
1. Remove clutch as outlined previously in this chapter.
2. Install handle end of piston pin puller (PN 2870386)
securely into bench vise and lightly grease puller
threads.
3. Remove nut from puller rod and set aside.
4. Install puller adapter (Item 10 from kit 2871226).
5. Install main adapter (Item D) onto puller.
6. With towers pointing toward the vise, slide sheave
onto puller rod.
7. Install removal tool (Item A/B) into center of sheave
with "A side" toward sheave.
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.
6.42
- projex@inbox.lv -
Part No.
5132027
5132501
5132029
5132028
9915111
Puller Tool (A/B)
Side "A" toward
sheave
Main Adapter
(D)
Nut (C)
Puller Adapter (10)
Piston Pin
Puller