Troubleshooting - Polaris 2005 Sportsman MV7 Service Manual

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.

TROUBLESHOOTING

Situation
Engine RPM -Wrong or broken drive clutch spring.
below specified
operating range -Drive clutch shift weight too heavy.
although engine
is properly -Driven clutch spring broken or installed
tuned. wrong .
Erratic engine -Drive clutch binding.
operating RPM
during accelera-
tion or load vari-
ations.
-Belt worn unevenly - thin/burnt spots
-Driven clutch malfunction.
-Sheave face grooved.
Nut (C)
Adapter
Reducer (9)
Piston Pin
Puller
Probable Cause
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.
Remedy
-Replace with recommended spring.
-Install correct shift weight kit to match engine application.
-Replace spring; refer to proper installation location.
a. Disassemble drive clutch; inspect shift weights for wear
and free operation.
b. Clean and polish stationary shaft hub; reassemble clutch
without spring to determine problem area.
Replace belt
a. Replace ramp buttons.
b. Inspect movable sheave for excessive bushing clearance/
replace.
-Replace the clutch.
CLUTCH
6.27