Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 164 / 289

CLUTCH
6.22
DRIVEN CLUTCH MOVEABLE
SHEAVE - BUSHING
REMOVAL
NOTE: Bushings are installed at the factory using
Loctite
t
. In order to remove the bushing it will be
necessary to apply heat. A press can be used to
remove and install some of the bushings. Be sure to
support the sheave or cover as close as possible to
the bushing bore when using a press.
Main Puller Adapter (#8)
Adapter
Reducer (#9)
Piston Pin Puller
( PN 2870386 )
1. Install Main Puller Adapter (#8) ( PN 5020632 )
onto the Piston Pin Puller ( PN 2870386) .
2. Insert Adapter Reducer (#9) ( PN 5010279 ) onto
the puller, sliding it inside the main adapter.
3. Remove ramp buttons from moveable sheave.
4. Using an electric or hand held propane torch,
apply heat directly on bushing until tiny smoke
tailings appear.
CAUTION:
Clutch components will be hot! In order to avoid
serious burns, wear some type of insulated gloves for
the rest of the removal process.
Clutch Bushing
Removal Tool (#5)
5. Working from the top, install Driven Clutch
Bushing Removal Tool (#5) ( PN 5020631 ) into the
center of clutch sheave with smaller diameter
toward bushing to be removed. See illustration at
above.