Clutch Bushing Replacement Tool Kit - Polaris 2005 SPORTSMAN 500 Servise Manual

2. Lift one-way clutch off shaft.
assembly if worn, damaged, or if problems were
noted.
3. Inspect surface of shaft for pitting, grooves, or
damage. Measure the outside diameter and
compare to specifications. Replace the drive
clutch assembly if shaft is worn or damaged.
Shaft Diameter
Standard: 1.3745" - 1.375"
Service Limit: 1.3730"
4. Remove 2 1/2" PTFE washer from shaft. Visually
inspect the washer for damage. Measure the
thickness and compare to specification. Replace
if worn or damaged.
PTFE Washer Thickness
Standard: .030" (.76mm)
Service Limit: .025" (.64mm)
EBS - - MOVEABLE SHEAVE
Replace as an
BUSHING INSPECTION
1. Inspect the Teflont coating on the moveable
sheave bushing. Inspect BOTH sheaves for signs
of wear, grooving or cracking. Clean surfaces with
a 3Mt pad if needed
EBS DRIVE BUSHING
SERVICE
EBS CLUTCH BUSHING REMOVAL AND
INSTALLATION
The contents of this kit include:
Item
A/B
C
D
E
Also required: Clutch Bushing Replacement
Tool Kit (PN 2871226) (ATV Clutch Kit) or (PN
2871025) (For all clutches) Piston Pin Puller
(PN 2870386)
Moveable Sheave Bushing Inspection:
Replace the cover bushing if more
brass than Teflont is visible on the
bushing. Refer to bushing replacement
in this chapter.
(Use Tool Kit PN 2201379)
Qty Part Description
1 EBS Puller Tool
1 EBS Puller Nut
1 EBS Main Adapter 5132029
1 EBS Bushing
Removal Tool
1 Instructions
CLUTCHING
Part No
5132027
5132501
5132028
9915111
6.25