ENGINE
3.26
STARTER DRIVE
REMOVAL/INSPECTION
1.
Remove recoil housing bolts and remove
housing.
2.
Remove starter drive assembly. Note the thrust
washer located at the rear of the drive
mechanism.
3.
Inspect the thrust washer for wear or damage and
replace if necessary.
4.
Measure the OD of the starter drive shaft on both
ends and record.
Std. Bushing ID:
.4735
²
-.4740
²
(11.11-12.04 mm)
Std. Shaft OD:
.470
²
-.472
²
(11.93-11.99 mm)
5.
Measure the ID of the bushing in the recoil
housing (A) and in the crankcase and record.
Measure in two directions 90
°
apart to determine
if bushing is out of round.
Calculate bushing
clearance. Replace bushing if clearance exceeds
the service limit.
A
Starter Drive Bushing Clearance:
Std: .0015
²
-.004
²
(.038-.102 mm)
Service Limit:
008
²
(.203 mm)
6.
Inspect gear teeth on starter drive.
Replace
starter drive if gear teeth are cracked, worn, or
broken.
FLYWHEEL/STATOR
REMOVAL/INSPECTION
1.
Remove flywheel nut and washer.
A
2.
Install Flywheel Puller (
PN 2871043
) and remove
flywheel.
CAUTION:
Do not thread the puller
bolts into the flywheel more than 1/4
²
or stator
coils may be damaged.
3.
Mark or note position of stator plate on crankcase.
4.
Remove bolts and carefully remove stator
assembly, being careful not to damage crankshaft
bushing on stator plate.
Summary of Contents for TRAIL BOSS 2003
Page 5: ......
Page 8: ...GENERAL INFORMATION 1 3 2003 TRAILBOSS MODEL 2003 TRAILBOSS 330 ...
Page 17: ...GENERAL INFORMATION 1 12 NOTES ...
Page 105: ...FUEL SYSTEM CARBURETION 4 14 NOTES ...
Page 153: ...FINAL DRIVE 7 12 NOTES ...
Page 213: ...ELECTRICAL 10 25 WIRING DIAGRAM 2003 TRAILBOSS 330 ...