Polaris 2007 Sportsman 450 EFI, Service Manual

Page: 210 / 406

6.20
CLUTCH SYSTEM
Cover Bushing Removal
1. Install main adapter (Item 8) on puller.
2. Install adapter reducer (Item 9).
3. From outside of clutch cover, insert removal tool (Item 3)
into cover bushing.
4. With inside of cover toward vise, slide cover onto puller.
5. Install nut onto puller rod and hand tighten. Turn puller
barrel to increase tension as needed.
6. Turn clutch cover counterclockwise on puller rod until
bushing is removed and cover comes free.
7. Remove nut from puller rod and set aside.
8. Remove bushing and bushing removal tool from puller.
Discard bushing.
Cover Bushing Installation
1. Apply Loctite
™
609 evenly to bushing bore in cover.
2. Working from inside of cover, insert new bushing and
bushing installation tool into center of clutch cover.
3. With main adapter on puller, insert cover onto puller rod,
placing outside of cover toward vise.
4. Install nut on rod and hand tighten. Turn puller barrel to
apply more tension if needed.
5. Turn clutch cover counterclockwise on puller rod until
bushing is seated.
6. Remove nut from puller rod. Take installation tool and
clutch cover off rod.
One-Way Clutch Inspection (Drive Clutch)
1. Rotate one-way clutch clockwise (as viewed from the
cover plate side). The clutch should rotate on the shaft
with only slight amount of drag. Verify there is no binding
or rough spots. When rotated counterclockwise, the clutch
should lock to the shaft without slipping. If problems are
noted in either direction, continue with disassembly.
Drive Clutch Reassembly
NOTE: It is important that the same number and
thickness of washers are reinstalled beneath the
spider during assembly. The Teflon bushings are
self-lubricating.
1. Reassemble drive clutch in the following sequence. Be
sure the “X”, or the marks that were made earlier, are
aligned during each phase of assembly.
A) “X”, or the marks that were made earlier on cover
B) “X” on spider, making sure spacer washers are installed
underneath spider and positioned properly in recess
Removal Tool (3)
Nut (C)
Adapter Reducer (9)
Piston Pin Pulle
Main Adapter (8)
CAUTION
Do not apply oil or grease to the bushings.