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Polaris 2005 SPORTSMAN 400 - Bushing Service

Polaris 2005 SPORTSMAN 400
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CLUTCHING
6.22
NON--EBS -- DRIVEN CLUTCH
BUSHING SER
VICE
NOTE: Bushings are installed at the factory using
Loctitet. 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.

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