2005 Polaris Sportsman 400/500 Service Manual, Page 177Get this manual
CLUTCHING REMOVAL AND INSTALLATION INSTRUCTIONS NOTE: Bushings are installed at the factory using Loctitet 609In order to remove bushings it will be necessary to apply heat evenly to the area around each bushingClean all residual Loctite from bushing bore prior to installing new bushingEBS Drive Clutch Moveable Sheave Bushing Removal 1Remove clutch as outlined previously in this chapter2Install handle end of Piston Pin Puller (PN 2870386) securely into bench vise and lightly grease puller threads3Remove nut from puller rod and set aside4Install puller adapter (Item 10 from kit PN 2871226)5Install main adapter (Item D) onto pullerPuller Tool (AB) Side "A" toward sheave Bushing Main Adapter (8) Piston Pin Puller 1Place main adapter (Item 8) on pullerPuller Tool (AB) Side "A" toward sheave Nut (C)
EBS Drive Clutch Moveable Sheave Bushing Installation 2Apply Loctitet 609 evenly to bushing bore inside moveable sheave3Set bushing in place on sheave4Insert installation puller tool (Item AB) with "A" side down, into center of bushing5With towers pointing upward, slide sheave, bushing and tool onto puller rod6Install nut on puller rod and hand tightenTurn barrel to apply additional tension if needed7Turn sheave counterclockwise, making sure bushing is drawn straight into boreContinue until bushing is seated8Remove nut from puller rod and set aside9Remove sheave from puller10Remove installation toolEBS Drive Clutch Cover Bushing Removal 1Install main adapter (Item 8) on puller