Polaris Outlaw 500, Service Manual

Page: 67 / 202

3.20
ENGINE
3. Removing the flywheel exposes the starter drive main gear
and one way clutch, which is mounted on the flywheel.
Inspect the main gear and bearing for wear, broken teeth or
other damage. Inspect the one-way clutch for wear or
damage to the rollers, springs, etc. Replace one-way
assembly if excessive wear or damage is found.
4. To replace the one-way starter clutch, remove the 8 screws
(A) holding the assembly to the flywheel. Reinstall the
screws and torque to 155-133 in. lbs. (13-15 Nm) in a criss-
cross pattern.
5. Installation: For installation of flywheel and starter gears,
reverse the removal procedures. When installing the
flywheel, apply engine oil to the crankshaft threads and
torque the flywheel nut to 111-125 ft. lbs. (150-170 Nm).
Crankshaft Nut Removal
1. Remove the stator-side crankshaft nut using MAG End
Crankshaft Nut Remover/Installer
(PN PA-46076) while
using a suitable holding fixture to keep the crankshaft from
turning.
2. To reinstall, use a suitable holding fixture and MAG End
Crankshaft Nut Remover/Installer (PN PA-46076) to
torque the nut to 66-81 ft. lbs. (90–110 Nm).
Clutch Cover / Clutch Removal and
Inspection
1. Remove the 12 screws holding the clutch cover.
2. Remove the gasket. Clean the gasket surfaces prior to
reassembly.
A
PA
-46
076
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