2008 Polaris Sportsman 500 EFI/X2/Touring/500 H.O. Service Manual, Page 225Get this manual
CLUTCH SYSTEM Drive Clutch Bushing Installation 12Place main adapter on pullerApply Loctite 609 evenly to bushing bore inside moveable sheave3Set bushing in place on sheave4Insert installation puller tool 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 toolCover Bushing Removal 12345678Install main adapter on pullerInstall adapter reducerFrom outside of clutch cover, insert removal tool into cover bushingWith inside of cover toward vise, slide cover onto pullerInstall nut onto puller rod and hand tightenTurn puller barrel to increase tension as neededTurn clutch cover counterclockwise on puller rod until bushing is removed and cover comes freeRemove nut from puller rod and set asideRemove bushing and bushing removal tool from pullerDiscard bushing123Install moveable sheave onto fixed sheaveInstall spider spacersUse same quantity and thickness as were removedCompress spider buttons for each tower and install spider towers on the moveable sheaveVerify that the alignment marks on spider align with the marks that were made on the moveable sheaveTorque spider to specification using the holding fixture and spider toolTorque with smooth motion to avoid damage to the stationary sheave