2001 Polaris Sportsman 400-500 DUSE and H.O. Service Manual, Page 229Get this manual
BUSHING REPLACEMENT, EBS DRIVEN, CONTEBS DrivenBackside (Outer) Bushing Removal 1Install main puller adapter (Item 8) onto puller2Install adapter reducer (Item 9)3Using hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appearCAUTION: Clutch components will be hot! In order to avoid serious burns, wear some type of insulated gloves for the rest of the removal process4Flip sheave over onto puller5Install bushing tool (Item 2)
Heat Bushing Surface Prior To Installation Removal OF Bushings 6Install left hand nut (C) and spacer onto puller rod and tighten by handTurn puller barrel for further tension if needed7Turn clutch sheave counterclockwise until bushing is removed and sheave comes free8Remove nut (C) (left hand thread) from puller rod and set aside9Remove adapters from puller10Remove bushing and removal tool from adaptersDiscard bushingEBS DrivenBackside (Outer) Bushing Installation 1Install puller adapter (Item 10) onto puller2Install adapter (Item 9) onto puller3Apply Loctite 609 evenly to bushing bore inside moveable sheave4Install sheave face down on puller5Install new bushing on installation tool (Item 2) and install assembly into sheave6Install left hand thread nut (C) onto puller rod and hand tighten against installation tool7Turn clutch sheave counterclockwise, making sure bushing is drawn straight into boreContinue until bushing is seated8Remove nut (C) (left hand thread) from puller rod and set aside9Remove installation tool and clutch sheave from pullerNut (C) Bushing Tool (2) Bushing Adapter Reducer (9) Main Adapter (8) EBS Driven Clutch Outer Bushing Removal Bushing Tool (2)