6.32
CLUTCHING
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Bushing Service
Bushings are installed at the factory using Loctite™. 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.
1. Remove ramp buttons from moveable sheave.
2. Install Main Puller Adapter (#8) (PN 5020632) onto
the Piston Pin Puller (PN 2870386).
3. Insert Adapter Reducer (#9) (PN 5010279) onto the
puller, sliding it inside the main adapter.
4. Using an appropriate heat gun, apply heat directly on
bushing until tiny smoke tailings appear.
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.
6. Install sheave onto puller.
7. Install nut onto puller rod and tighten by hand. Turn
puller barrel for further tension if needed.
8. Turn clutch sheave counterclockwise until bushing is
removed. Repeat Steps 5 - 8 for other bushing.
9. Remove nut from puller rod and set aside.
10. Remove adapters from puller.
11. Remove bushing and removal tool from adapters.
Discard bushing.
Clutch components will be hot! In order to avoid
serious burns, wear heat resistant insulated
gloves for the rest of the removal process.
Piston Pin Puller
(PN 2870386)
Main Puller Adaptor (#8)
Adapter
Reducer (#9)
Clutch Bushing
Removal Tool (#5)
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