Drive Clutch Bushing Service - Polaris SPORTSMAN 400 2003 Service Manual

DRIVE CLUTCH BUSHING
SERVICE
*Clutch Bushing Replacement Tool Kit (PN
2871226)
Stamp Qty. Part Desciption
#2 1 P--90 Drive/Driven
Cluth Bushing Install
#3 1 Drive Clutch Cover
Bushing Removal/
Installation Tool (all
clutches)
#5 1 P--90 Driven Clutch
Cover Bushing Re-
moval Tool
#8 1 Main Puller Adapter
#9 1 Adapter Reducer
#10 1 Number Two Puller
DRIVE CLUTCH MOVEABLE
SHEAVE - BUSHING
REMOVAL
#3
#2
#10
#8
1. Install handle end of the Piston Pin Puller (PN
2870386) securely into bench vise and lightly
grease puller threads.
Piston Pin Puller (PN 2870386)
Part #
5020628
Tool
5020629
5020631
5020632
5010279
5020633
Adapter
#5
#9
2. Remove nut from puller rod and set aside.
Piston Pin Puller
(PN 2870386)
Main Puller Adaptor (#8)
3. Install the Main Puller Adapter (#8) (PN 5020632)
onto the Piston Pin Puller (PN 2870386).
4. Insert the Number Two Adapter (#10) (PN
5020633) into the bushing from belt side as
shown. With towers pointing toward vise, slide
sheave and bushing onto puller rod.
5. Install the nut removed in Step 2 onto end of puller
rod and hand tighten.
increase tension on sheave if needed. Nut is left
hand thread
6. Turn sheave and
counterclockwise on puller rod until bushing is
removed.
7. Remove nut from puller rod and set aside.
CLUTCH
Turn puller barrel to
puller barrel together
6.17