So after this season I think I'm going to pull my primary and check it over. Aside from buying a few tools, the rebuild should be straight forward? I saw a YouTube video from EPI.

The rebuild kits, are they all the same? I see EPI sells a primary rebuild kit. I do not have EBS.

I will also check the secondary out, is it just buttons that need attention?

I think I will add a clutch kit too, my 400HO will get a helix for the secondary.

I did notice a small groove in my primary where the belt rests, this ok?

 

Basically all non ebs clutches are the same. Any kit on ebay will work,even better if you get the kit with the two bushings,one for the cover,one for the inner sheath. Normal to have some small grooving on the drive clutch from the belt.

 

Thanks OPT. I don't mind buying the tools because I plan on staying with Polaris.

Would a dead blow hammer be a better choice for tapping the pins in that the rollers slide on?

 

You can over board with a dead blow. Just use a brass hammer if you have one along with a punch if needed.Just support the towers with your fingers sort of like when punching out a carb float pin. No worse feeling than to break a carb body float pin casting from too much pressure and no support.

 

Thanks OPT. What would you use to knock the cover bushings out? Sockets? Where can dies be bought?

 

Of course the easiest way to change and install the bushings is to use the specialty tools designed for them like I had at the shop. Clutch Bushing Replacement Tool Kit They use a piston pin puller tool to pull bushings out along with seating the new ones.But most people have resorted to modifying sockets,etc to do this. Even the cheap bearing and seal installer sets can somewhat help on removing and seating new bushings,but you may still have to break out the punches. The hard part is to keep from nicking or flaring out the new bushings when installing.This will do nothing but cause clutches to stick and not operate correctly. The expensive oem kit makes this job a breeze. To be honest with you,you can install the pins,guide buttons,etc ,but might be to your advantage to take the clutch outer cover and main clutch body in and let a dealer pull out and install the two bushings. Shouldn't cost but a few bucks and you don't have to invest in expensive tools for a one time use.

 

Thanks OPT. I emailed my dealer, they can do it no problem.