Crankcase Disassembly; Starter Drive Removal/Inspection - Polaris Trail Blazer Service Manual

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Engine Disassembly, Cont.

Crankcase Disassembly

NOTE: The recoil starter, starter motor, starter drive,

flywheel, stator, cam chain and sprockets can be serv-

iced with the engine in the frame.

1. Remove recoil housing bolts and remove housing.

2. Remove starter drive assembly.

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

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

Calculate bushing clearance.

bushing if clearance exceeds the service limit.

Std. Bushing ID:

.4735"-.4740" (11.11-12.04 mm)

Std. Shaft OD:

.470"-.472" (11.93-11.99 mm)

Starter Drive Bushing Clearance:

Std: .0015"-.004" (.038-.102 mm)

Service Limit:

.008" (.203 mm)

Polaris Sales Inc.

Note the thrust

ES33PF, EH50PL Engine