Polaris SPORTSMAN 600 Service Manual page 167

LATE 2004 - - EBS DRIVE
BUSHING SERVICE
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 Puller Tool
C 1 EBS Puller Nut
D 1 EBS Main Adapter 5132029
E 1 EBS Bushing
Removal Tool
1 Instructions
Also required: Clutch Bushing Replacement
Tool Kit (PN 2871226) (ATV Clutch Kit) or (PN
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 installing 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 PN
2871226).
5. Install main adapter (Item D) onto puller.
Puller Tool (A/B)
Side "A" toward
sheave
Main Adapter
(D)
Part No
5132027
5132501
5132028
9915111
Nut (C)
Puller Adapter (10)
Piston Pin
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.
EBS Drive Moveable Bushing Installation
1. Place main adapter (Item 8) on puller.
Puller Tool (A/B)
Side "A" toward
sheave
Bushing
Main Adapter
(8)
EBS Drive Clutch Moveable Sheave
Bushing Installation
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.
CLUTCH
Nut (C)
Piston Pin
Puller
6.29