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9924707 - 2013–2014 RZR 800 Service Manual
© Copyright 2013 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 counter-clockwise 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 counter-clockwise on puller rod
until bushing is seated.
6. Remove nut from puller rod. Take installation tool
and clutch cover off rod.
Clutch Assembly
NOTE: The Teflon™ bushings are self-lubricating.
CAUTION
Do not apply oil or grease to the bushings.
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 the PTFE washers and bearing over the clutch
shaft. There should be one PTFE washer on each
side of the bearing.
2. Install the moveable sheave and spacer onto the
clutch shaft.
NOTE: To maintain proper clutch balance and
belt-to-sheave clearance, be sure to reinstall the
original quantity and thickness of washers/
spacers beneath the spider during assembly.
CLUTCHING
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