Polaris Sportsman 400 Service Manual page 227

BUSHING REPLACEMENT, EBS DRIVE, CONT.
EBS Drive Moveable - Bushing Installation
1. Place main adapter (Item 8) on puller.
2. Apply Loctitet 609 evenly to bushing bore inside
moveable sheave.
3. Set bushing in place on sheave.
4. Insert installation puller tool (Item A/B) with "A" side
down, into center of bushing.
5. With towers pointing upward, slide sheave, bushing
and tool onto puller rod.
6. Install nut on puller rod and hand tighten. Turn barrel
to apply additional tension if needed.
7. Turn sheave counterclockwise, making sure bushing
is drawn straight into bore. Continue until bushing is
seated.
8. Remove nut from puller rod and set aside.
9. Remove sheave from puller.
10. Remove installation tool.
EBS Clutch Cover - Bushing Removal
1. Install main adapter (Item 8) on puller.
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 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 and take installation tool and clutch cover off rod.
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Puller Tool (A/B)
Side "A" toward
sheave
Bushing
Main Adapter
(8)
EBS Drive Clutch Moveable Sheave
Bushing Installation
Removal Tool (3)
Main Adapter
(8)
EBS Drive Clutch Cover Bushing Removal
CLUTCH
Nut (C)
Piston Pin
Puller
Nut (C)
Adapter
Reducer (9)
Piston Pin
Puller
6.43