Polaris SPORTSMAN 400 2003 Service Manual page 162

8. Remove nut (C) (left hand thread) from puller rod
and set aside.
9. Remove adapters from puller.
10. Remove bushing and removal tool from adapters.
Discard bushing.
EBS Driven - Bushing Installation
1. Slide adapter (Item 10) onto puller.
EBS Driven Clutch Bushing Installation
Puller Tool (A/B)
Side "B" toward
sheave
Bushing
2. Apply Loctitet 609 evenly to bushing bore inside
moveable sheave.
3. Install sheave onto puller (belt surface up).
4. Place new bushing on side B of installation tool
(Item A/B) and slide both over puller rod.
5. Install nut (C) onto puller rod and hand tighten
against installation tool.
6. Turn clutch sheave counterclockwise until
bushing is seated.
7. Remove nut (C) (left hand thread) from puller rod
and set aside.
8. Remove installation tool and clutch sheave from
puller.
EBS Driven - Backside (Outer) Bushing Removal
1. Install main puller adapter (Item 8) onto puller.
2. Install adapter reducer (Item 9).
3. Using a hand held propane torch, apply heat
around outside of bushing until tiny smoke tailings
appear.
CAUTION: Clutch components will be hot! In
order to avoid serious burns, wear insulated
gloves during the removal process.
4. Flip sheave over onto puller.
5. Install bushing tool (Item 2).
6. Install left hand nut (C) and spacer onto puller rod
and tighten by hand. Turn puller barrel for further
tension if needed.
Nut (C)
Puller Adapter (10)
7. Turn clutch sheave counterclockwise until
bushing is removed and sheave comes free.
8. Remove nut (C) (left hand thread) from puller rod
and set aside.
9. Remove adapters from puller.
EBS Driven Clutch Outer Bushing Removal
Bushing
Tool (2)
Main Adapter
(8)
10. Remove bushing and removal tool from adapters.
Discard bushing.
EBS Driven - Backside (Outer) Bushing
Installation
1. Install puller adapter (Item 10) onto puller.
2. Install adapter (Item 9) onto puller.
EBS Driven Clutch OuterBushing Installation
Bushing
Tool (2)
Bushing
Tool (2)
Puller Adapter
(10)
3. Apply Loctitet 609 evenly to bushing bore inside
moveable sheave.
4. Install sheave face down on puller.
5. Install new bushing on installation tool (Item 2)
and install assembly into sheave.
6. Install left hand thread nut (C) onto puller rod and
hand tighten against installation tool.
7. Turn clutch sheave counterclockwise, making
sure bushing is drawn straight into bore.
Continue until bushing is seated. (Go to next
page)
CLUTCH
Nut (C)
Adapter
Reducer (9)
Nut (C)
Bushing
Adapter
(9)
6.31