Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 160 / 289

CLUTCH
6.18
6. Turn sheave and puller barrel together
counterclockwise on puller rod until bushing is
removed.
7. Remove nut from puller rod and set aside.
8. Pull bushing removal tool and adapter from puller
rod. Remove bushing from tool and discard.
DRIVE CLUTCH MOVEABLE
SHEAVE - BUSHING
INSTALLATION
1. Place the Main Puller Adapter (#8) ( PN 5020632 )
onto the puller.
2. Apply Loctite
t
680 ( PN 2870584 ) to the back
side of new bushing. Push bushing into center of
sheave on tower side by hand.
Bushing (PN 3576504)
Loctite
t
680 (PN 2870584)
3. Insert the Clutch Bushing Installation Tool (#2) ( PN
5020628 ) into center of sheave and with towers
pointing away from vise, slide sheave onto puller
rod.
4. Install nut on puller rod and hand tighten. Turn
barrel to apply additional tension if needed.
5. Turn sheave and barrel together
counterclockwise until bushing is seated.
6. Remove nut from puller rod and set aside.
7. Remove sheave from puller.
8. Remove installation tool.
DRIVE CLUTCH COVER -
BUSHING REMOVAL
Main Puller
Adaptor (#8)
Piston Pin Puller
( PN 2870386 )
1. Install the Main Puller Adapter (#8) ( PN 5020632 )
onto the Piston Pin Puller ( PN 2870386 ).
2. From outside of clutch cover, insert the Drive
Cover Bushing Remover (#3) ( PN 5020629 ) into
cover bushing.
3. With inside of cover toward vise, slide cover onto
puller.
4. Install nut onto puller rod and hand tighten. Turn
puller barrel to increase tension as needed.