2007 Polaris Sportsman 700/800/800 X2 EFI Service Manual, Page 201Get this manual
CLUTCH SYSTEM SheaveBushing Inspection
Inspect the Teflon( coating on the sheave bushings and cover bushingInspect BOTH sheaves for signs of wear, grooving or crackingClean sheave surfaces with 3M( pad if neededNOTE: Bushings are installed at the factory using Loctite( 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 bushing
CAUTION
Clutch components will be hot! In order to avoid serious burns, wear insulated gloves during the removal processDrive Clutch Bushing Removal 12Remove clutch as outlined previously in this chapterInstall 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 onto puller6With towers pointing toward the vise, slide sheave onto puller rod7Install removal tool into center of sheave8Install nut onto end of puller rod and hand tightenTurn puller barrel to increase tension on sheave if neededUsing hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear9Turn sheave counterclockwise on puller rod until it comes freeLift sheave off puller10Remove nut from puller rod and set aside11Pull bushing removal tool and adapter from puller rodRemove bushing from tool and discard