Polaris Sportsman XP 1000 S 2021 - Page 278

6.20
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
2. Install handle end of the Piston Pin Puller securely
into bench vise and lightly grease puller threads.
Piston Pin Puller
2870386
3. Remove nut from puller rod and set aside.
4. Install Puller Adapter
a
from kit (PN 2871226).
5. Install Main Adapter (D) onto puller.
6. With towers pointing toward the vise, slide sheave
onto puller rod.
7. Insert Bushing Tool (PA-47336) with small side down,
into center of sheave.
8. Install Nut (C) onto end of puller rod and hand tighten.
Turn 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. Turn 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.
MOVEABLE SHEAVE – BUSHING
INSTALLATION
1. Apply Loctite® 648 evenly to bushing bore inside
moveable sheave.
2. Set bushing in place on sheave.
3. Insert Bushing Tool (PA-47336) with small side down,
into center of bushing.
4. With towers pointing upward, slide sheave, bushing
and tool onto puller rod.
5. Install nut onto puller rod and hand tighten. Turn
puller barrel to increase tension on sheave if needed.
6. Turn sheave counterclockwise, making sure bushing
is drawn straight into bore. Continue until bushing is
seated.
7. Remove nut from puller rod and set aside.
8. Remove sheave from puller.
9. Remove installation tool.
COVER BUSHING REMOVAL
1. Install Main Adapter
i
onto puller.
2. Install Adapter Reducer
o
.
3. From outside of clutch cover, insert Removal Tool
e
into cover bushing.
4. With inside of cover toward vise, slide cover onto
puller.
5. Install Nut (C) onto puller rod and hand tighten. Turn
puller barrel to increase tension on sheave if needed.
6. Turn clutch cover counterclockwise on puller rod until
bushing is removed and cover comes free.
7. Remove nut from puller rod and set aside.
PVT SYSTEM