7.20
PVT System
9923396 - 2007-2012 EDGE/Widetrak LX Service Manual
©2011 Polaris Sales Inc.
Bushing/Insert Replacement
The drive clutch moveable sheave and cover bushings /
insert are replaceable. Bushing/insert removal and
installation can be aided using Bushing Removal and
Installation Kit.
The kit uses the Piston Pin Puller tool. Each of the
adapters and/or tools are marked with an item number.
The item number is referenced within the text for
identification.
Moveable Sheave Bushing/Insert Removal
and Installation
NOTE: A torch may be required to release the
bushing retaining compound.
1.
Disassemble the clutch and remove the moveable
sheave from the stationary shaft.
2.
Install handle end of the piston pin puller securely into
a bench vise.
3.
Install the main adapter (Item 8) onto the puller.
4.
Working from inside of moveable sheave, insert the
moveable sheave removal tool (Item 1) into the center
of the sheave. Slide sheave onto puller tool with
towers facing upwards.
5.
Secure puller nut. turn puller barrel to increase tension
on the sheave if required.
6.
Turn sheave counterclockwise on puller rod until it
comes free.
7.
Remove the sheave from the puller tool rod.
8.
Remove and discard the old bushing and insert.
9.
To install a new bushing, place the main adapter (Item
8) onto the puller rod.
10. Apply a thin film of Loctite 648 to the leading edge of
the new bushing. Push a new bushing into center of
sheave by hand.
NOTE: Verify no retaining compound is deposited on
the I.D. of the bushing.
11. Insert installation tool (Item 1) into center of sheave
and with the towers pointing toward the vise (down),
slide the sheave onto the puller rod.
12. Secure rod nut. turn barrel to apply additional tension
against sheave if required.
13. Turn the sheave counterclockwise until bushing is
fully seated.
14. Remove the rod nut and installation tool and repeat
steps 11 to 13 and install the new insert.
Cover Bushing
NOTE: A torch may be required to release the
bushing retaining compound.
1.
On covers utilizing a retaining ring, remove the ring
using a pick or scribe.
2.
Install the main adapter (Item 8) onto the puller tool.
3.
From outside of the cover, insert the removal tool
(Item 3) into the cover bushing.
4.
With the inside of the cover facing the vise, slide the
cover onto the puller.
5.
Secure the rod nut. Turn the puller barrel to apply
tension if required.
6.
Turn the clutch cover counterclockwise until the
bushing is removed and the cover comes free.
7.
Remove the tools and discard the bushing.
8.
To install a new cover bushing, apply Loctite 648 to
the leading edge of the new bushing. Insert the new
bushing and bushing installation tool (Item 3) from the
inside of the cover.
NOTE: Verify no retaining compound is deposited on
the I.D. of the bushing.
9.
With the main adapter (Item 8) installed on the puller,
insert the cover onto the puller rod with the outside of
the cover facing the vise.
10. Secure the rod nut and tighten the puller barrel to
apply more tension if required.
11. Turn the clutch cover counterclockwise on the puller
rod until the bushing is fully seated. Remove the tools
from the rod and remove cover.
12. Squeeze the ends of the retaining ring and reinstall
into the back of the cover.
Clutch Bushing Removal / Installation Kit
PN 2871025
Individual Parts:
P-85 Bushing / Insert Tool = 5020627 (Item 1)
Cover Bushing Tool = 5020629 (Item 3)
Main Puller Adapter = 5020632 (Item 8)
Piston Pin Puller Tool
PN 2870386
