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7.20 PVT System 9923396 - 2007-2012 EDGE/Widetrak LX Service Manual ©2011 Polaris Sales Inc. Bushing/Insert Replacement The drive clutch moveable sheave and cover bushings / The kit uses the Piston Pin Puller tool. Each of the Moveable Sheave Bushing/Insert Removal and Installation NOTE: A torch may be required to release the 1. Disassemble the clutch and remove the moveable 2. Install handle end of the piston pin puller securely into 3. Install the main adapter (Item 8) onto the puller. 4. Working from inside of moveable sheave, insert the 5. Secure puller nut. turn puller barrel to increase tension 6. Turn sheave counterclockwise on puller rod until it 7. Remove the sheave from the puller tool rod. 8. Remove and discard the old bushing and insert. 9. To install a new bushing, place the main adapter (Item 10. Apply a thin film of Loctite 648 to the leading edge of the new bushing. Push a new bushing into center of NOTE: Verify no retaining compound is deposited on 11. Insert installation tool (Item 1) into center of sheave and with the towers pointing toward the vise (down), 12. Secure rod nut. turn barrel to apply additional tension against sheave if required. 13. Turn the sheave counterclockwise until bushing is fully seated. 14. Remove the rod nut and installation tool and repeat steps 11 to 13 and install the new insert. Cover Bushing NOTE: A torch may be required to release the 1. On covers utilizing a retaining ring, remove the ring 2. Install the main adapter (Item 8) onto the puller tool. 3. From outside of the cover, insert the removal tool 4. With the inside of the cover facing the vise, slide the 5. Secure the rod nut. Turn the puller barrel to apply 6. Turn the clutch cover counterclockwise until the 7. Remove the tools and discard the bushing. 8. To install a new cover bushing, apply Loctite 648 to NOTE: Verify no retaining compound is deposited on 9. With the main adapter (Item 8) installed on the puller, 10. Secure the rod nut and tighten the puller barrel to apply more tension if required. 11. Turn the clutch cover counterclockwise on the puller rod until the bushing is fully seated. Remove the tools 12. Squeeze the ends of the retaining ring and reinstall into the back of the cover. Clutch Bushing Removal / Installation Kit PN 2871025 Individual Parts: P-85 Bushing / Insert Tool = 5020627 (Item 1) Cover Bushing Tool = 5020629 (Item 3) Main Puller Adapter = 5020632 (Item 8) Piston Pin Puller Tool PN 2870386 |