Polaris Sportsman 400 - Page 226

CLUTCH
6.42
BUSHING REPLACEMENT, EBS DRIVE
EBS CLUTCH BUSHING REMOVAL AND INSTALLATION
Use Tool Kit PN 2201379
The contents of this kit include:
Item
Qty. Part Description Part No.
A/B 1 EBS Drive Clutch and Driven Clutch 5132027
Puller Tool
C 1 EBS Drive Clutch and Driven Clutch 5132501
Puller Nut
D 1 EBS Main Adapter 5132029
E 1 EBS Bushing Removal Tool 5132028
1 Instruction 9915111
Also required:
Clutch Bushing Removal/Installation Tool Kit PN 2871226 (A TV Clutch Kit) or 2871025 (For all clutches)
Piston pin puller (PN 2870386)
REMOVAL AND INSTALLATION INSTRUCTIONS
NOTE: Bushings areinstalledatthefactory using Loctitet 609. In order to removebushings itwillbenecessary
to apply heat evenly to the area around each bushing. Clean all residual Loctite from bushing bore prior to instal-
ling new bushing.
EBS Drive Clutch Moveable Sheave - Bushing Removal
1. Remove clutch as outlined previously in this chapter.
2. Install handle end of piston pin puller (PN 2870386)
securely into bench vise and lightly grease puller
threads.
3. Remove nut from puller rod and set aside.
4. Install puller adapter (Item 10 from kit 2871226).
5. Install main adapter (Item D) onto puller.
6. With towers pointing toward the vise, slide sheave
onto puller rod.
7. Install removal tool (Item A/B) into center of sheave
with “A side” toward sheave.
8. Install nut (C) onto end of puller rod and hand tighten.
T urn puller barrel to increase tension on sheave if
needed. Using a hand held propane torch, apply heat
around outside of bushing until tiny smoke tailings
appear.
9. T urn sheave counterclockwise on puller rod until it comes free. Lift sheave off puller .
10. Remove nut from puller rod and set aside.
11. Pull bushing removal tool and adapter from puller rod. Remove bushing from tool and discard.
Puller Adapter (10)
Main Adapter
(D)
Puller Tool (A/B)
Side “A” toward
sheave
Piston Pin
Puller
Nut (C)