Polaris 2007 SPORTSMAN X2 800 Service Manual page 189

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. Clean all residual Loctite
bushing bore prior to installing new bushing.
CAUTION
Clutch components will be hot! In order to avoid
serious burns, wear insulated gloves during the
removal process.
Drive Clutch 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)
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. NOTE: Smooth One-way Clutch
- Use Bushing Tool PA-47336.
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.
Drive Clutch Bushing Installation
1.
™
Puller Tool (A,B) Side
from
"A" toward sheave
2.
3.
Nut (C)
4.
5.
6.
7.
Puller
8.
Adapter (10)
9.
10. Remove installation tool.
Piston Pin
Puller
CLUTCH SYSTEM
Place main adapter (Item 8) on puller.
Bushing
Main Adapter (8)
Apply Loctite™ 609 evenly to bushing bore inside
moveable sheave.
Set bushing in place on sheave.
Insert installation puller tool (Item A/B) with "A" side
down, into center of bushing. NOTE: 800 EFI Clutch -
Use Bushing Tool PA-47336.
With towers pointing upward, slide sheave, bushing and
tool onto puller rod.
Install nut on puller rod and hand tighten. Turn barrel to
apply additional tension if needed.
Turn sheave counterclockwise, making sure bushing is
drawn straight into bore. Continue until bushing is seated.
Remove nut from puller rod and set aside.
Remove sheave from puller.
Nut (C)
Piston Pin Puller
6
6.19