Polaris 2011 RANGER RZR, Service Manual, Page: 246 / 418

6.19
CLUTCHING
6
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
© Copyright 2010 Polaris Sales Inc.
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.
Clutch Assembly
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.
Reassemble the drive clutch in the following sequence. Be sure
the “X”, or the marks that were made earlier are aligned during
each phase of assembly.
1. Install moveable sheave onto fixed sheave.
2. Install spider spacers. Use same quantity and thickness as
were removed.
3. Compress spider buttons for each tower and install spider,
making sure that “X”, or the marks that were made earlier,
on spider aligns with “X”, or the marks that were made
earlier, in moveable sheave.
Removal Tool
(3)
Nut (C)
Adapter Reducer
(9)
Piston Pin
Puller
Main
Adapter (8)
CAUTION
Do not apply oil or grease to the bushings.
Spacer washers