9850067 R01 - 2020-2021
GENERAL
/
GENERAL XP
Service Manual
© Copyright Polaris Inc.
3.59
FLYWHEEL INSTALLATION
1.
If previously removed, reinstall the flywheel key.
2.
Inspect and clean crankshaft and flywheel taper with
isopropyl
alcohol
or
similar
cleaning
solution.
Replace crankshaft if surface damage is present.
Clean taper of crankshaft to remove all oil or grease.
3.
Using an applicator, apply a 360 degree bead of
Loctite 641 (Yellow) to the internal taper surface on
the flywheel. Apply Loctite bead 5-6 mm from the
center of the taper, offset to the larger diameter of
the taper on the flywheel.
4.
Using an applicator, apply a 360 degree bead of
Loctite 641 (Yellow) to the external taper surface on
the crankshaft. Apply Loctite bead 5-6 mm from the
center of the taper and offset to the smaller end on
the crankshaft. Be careful to not apply any Loctite to
the starter gear bearing.
5.
Align flywheel key-way with key and install the
flywheel, seating it fully on taper.
6.
Install
flywheel
retaining
bolt
q
.
Using
a
commercially available strap wrench , hold flywheel
w
and torque the retaining bolt to specification.
NOTICE
If the Cylinder Holding & Camshaft Timing Plate (
PU-
50563
) is installed, remove it before tightening the
flywheel.
TORQUE
Flywheel Retaining Bolt:
129 ft-lbs (175 N·m)
7.
Wipe off excess Loctite and let stand for 1 hour
before starting engine.
NOTICE
Loctite cures with time, the longer the unit is let stand
before engine starting the better the joint will be.
8.
Install the starter torque limit gear as an assembly.
STATOR COVER INSTALLATION
1.
Apply gasket tack adhesive to help hold gasket in
place during assembly.
2.
Install a new stator cover gasket over alignment pins.
CAUTION
The flywheel contains powerful magnets. Use caution
when removing and installing the stator cover. DO NOT
place fingers between cover and crankcase at any time
during the removal / installation process or injury could
result.
3.
Install stator cover and thirteen screws. Torque
screws in sequence to specification.
TORQUE
Stator Cover Screws:
9 ft-lbs (12 N·m)
