Polaris TRAIL BOSS 325 2001 Manual page 93

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.
STARTER DRIVE REMOVAL/INSPECTION
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
and record.
5. Measure the ID of the bushing in the recoil housing (A)
and in the crankcase and record. Measure in two
directions 90q apart to determine if bushing is out of
round. Calculate bushing clearance.
bushing if clearance exceeds the service limit.
Std. Bushing ID:
.4735s-.4740s (11.11-12.04 mm)
Std. Shaft OD:
.470s-.472s (11.93-11.99 mm)
Starter Drive Bushing Clearance:
Std: .0015s-.004s (.038-.102 mm)
Service Limit:
.008s (.203 mm)
6. Inspect gear teeth on starter drive.
starter drive if gear teeth are cracked, worn, or
broken.
Note the thrust
Replace
Replace
ENGINE
A
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