Polaris PREDATOR 2003, Service Manual

Page: 68 / 193

ENGINE
3.25
5. Measure the ID of the bushing in the stator
housing (A) and the crankcase and record.
Measure in two directions 90
q
apart to determine
if cover is out of round. Replace cover if clearance
is determined to be excessive.
A
6. Inspect gear teeth on starter drive gears. Replace
gears if gear teeth are cracked, worn, or broken.
7. Installation: Reverse the removal procedures
and install with a new gasket. Do not use sealant.
Torque the bolts in a criss--cross pattern to 80-97
Inch Lbs.(9-11 Nm) .
FLYWHEEL AND ONE--WAY STARTER
CLUTCH REMOVAL/INSPECTION
1. Remove flywheel nut and washer.
2. Install Flywheel Puller (
PA--46075 ) and remove
flywheel. CAUTION: Thread the puller onto the
flywheel fully or flywheel threads may be
damaged.
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 holding the assembly to the flywheel
(A). Reinstall the screws and torque to 155--133
Inch Lbs. (13--15 Nm) in a criss--cross pattern.
A
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) .
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