Polaris 2005 SPORTSMAN 400, Servise Manual

Page: 174 / 312

CLUTCHING
6.22
NON--EBS -- DRIVEN CLUTCH
BUSHING SERVICE
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 a 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 heat resistant 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.