Starter One-Way Clutch Assembly; Flywheel Installation - Polaris GENERAL 2016 Service Manual

ENGINE / COOLING SYSTEM

STARTER ONE-WAY CLUTCH ASSEMBLY

1. Install one-way clutch in clutch hub with flange of
q
clutch engaged in recess.
2. Clean screw threads in flywheel to remove all oil or
grease.
3. Place one-way clutch on flywheel and install the
three screws. Torque screws to specification.
TORQUE
One-Way Clutch Retaining Screws:
9 ft-lb (12 Nm)
4. Reassemble starter one-way clutch and gear using
the following illustration.
q
Torque Limit Gear Pin
w
Starter Gear
e
One Way Clutch Asm.
r
Bolt 133 ft-lbs (180 Nm)
5. If starter gear was replaced, inspect the torque limit
gear.
6. After assembly, be sure the starter gear rotates in the
clockwise direction only.
3.72
t
Flywheel
y
Screws 9 ft-lb (12 Nm)
u
Torque Limit Gear Asm.

FLYWHEEL INSTALLATION

1. If previously removed, reinstall the flywheel key.
2. Inspect and clean crankshaft and flywheel taper with
isopropyl alcohol or similar cleaning solution.
Replace crankshaft if surface damage is present.
Clean taper of crankshaft to remove all oil or grease.
3. Using an applicator, apply a 360 degree bead of
Loctite 641 (Yellow) to the internal taper surface on
the flywheel. Apply Loctite bead 5-6 mm from the
center of the taper, offset to the larger diameter of
the taper on the flywheel.
4. Using an applicator, apply a 360 degree bead of
Loctite 641 (Yellow) to the external taper surface on
the crankshaft. Apply Loctite bead 5-6 mm from the
center of the taper and offset to the smaller end on
the crankshaft. Be careful to not apply any Loctite to
the starter gear bearing.
5. Align flywheel key-way with key and install the
flywheel, seating it fully on taper.
6. Install flywheel retaining
commercially available strap wrench , hold flywheel
w
and torque the retaining bolt to specification.
NOTICE
If the Cylinder Holding & Camshaft Timing Plate (PU-
50563) is installed, remove it before tightening the
flywheel.
TORQUE
Flywheel Retaining Bolt:
133 ft-lbs (180 Nm)
7. Wipe off excess Loctite and let stand for 1 hour
before starting engine.
NOTICE
Loctite cures with time, the longer the unit is let stand
before engine starting the better the joint will be.
9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual
q
bolt . Using
© Copyright Polaris Industries Inc.
a