Driven Clutch Bushing Removal/Installation - Polaris 2007 Sportsman 500 EF Service Manual

CLUTCH SYSTEM
12. Inspect the bearing for wear. Spin the bearing, if the
bearing does not spin smoothly replace as needed. To
remove the bearing, simply press the bearing from the shaft.
13. Inspect the bearing for wear. Spin the bearing, if the
bearing does not spin smoothly replace as needed. To
remove the bearing, simply press the bearing from the shaft.
Inspect Sheave Surface
14. Inspect the cam assembly (helix) bushing for wear. If the
bushing is worn or the shaft does not fit snug into the
bushing, replace the cam assembly (cover).
Inspect Bushing
DRIVEN CLUTCH BUSHING REMOVAL/
INSTALLATION
NOTE: Special Tool Required:
BUSHING REMOVAL AND INSTALLATION
Table 6-1:
I Q P D
TEM TY ART
A, B 1 EBS Puller Tool
C 1 EBS Puller Nut
D 1 EBS Main Adapter
EBS Bushing Removal
E 1
Tool Instructions
6.24
EBS CLUTCH
P
ESCRIPTION ART
5132027
5132501
5132029
5132028
I Q
TEM TY
-- 1
-- 1
-- 1
NOTE: Bushings are installed at the factory using
™
Loctite 609. In order to remove bushings it will be
necessary to apply heat evenly to the area around
each bushing.
bushing bore prior to installing new bushing.
Driven Clutch 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.
4. Flip sheave over so bushing faces downward and install
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.
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.
10. Remove bushing and removal tool from adapters. Discard
bushing.
Table 6-1:
P D
ART ESCRIPTION
Bushing Replacement Kit
Piston Pin Puller
Instructions
Clean all residual Loctite
P #
ART
2871226
2870386
9915111
™
from