Polaris Sportsman 400 - Page 228

CLUTCH
6.44
BUSHING REPLACEMENT, EBS DRIVEN
EBS Driven - Bushing Removal
1. Install puller adapter (Item 10) onto puller.
2. InsertEBSmainadapter (ItemD) ontopuller . SeeIll.1.
3. Install bushing removal tool (Item E) into center of
clutch sheave. See Ill. 2.
4. Install sheave onto puller.
5. Install left hand nut onto puller rod and tighten by
hand. Turnpuller barrelfor furthertension if needed.
6. Using a hand held propane torch, apply heat around
outside of bushing until tiny smoke tailings appear.
CAUTION: Clutch components will be hot! In order to
avoid serious burns, wear some type of insulated gloves
for the rest of the removal process.
7. T urnclutchsheave counterclockwiseuntil bushingis
removed and sheave comes free.
8. Removenut (C)(left handthread) frompullerrodand
set aside.
9. Remove adapters from puller.
10. Remove bushing and removal tool from adapters.
Discard bushing.
EBS Driven - Bushing Installation
1. Slide adapter (Item 10) onto puller.
2. Apply Loctitet 609 evenly to bushing bore inside
moveable sheave.
3. Install sheave onto puller (belt surface up).
4. Place new bushing onsideB of installation tool(Item
A/B) and slide both over puller rod.
5. Install nut (C) onto puller rod and hand tighten
against installation tool.
6. T urnclutchsheave counterclockwiseuntil bushingis
seated.
7. Removenut (C)(left handthread) frompullerrodand
set aside.
8. Remove installation tool and clutch sheave from
puller.
Ill. 1
D
Ill. 2
Bushing
Removal Tool (E)
Nut (C)
Bushing
EBS Driven Clutch Bushing Installation
Puller Adapter (10)
Puller Tool (A/B)
Side “B” toward
sheave