Polaris SPORTSMAN 400 2003 Service Manual page 83

ENGINE
Std. Bushing ID:
.4735²-.4740² (11.11-12.04 mm)
Std. Shaft OD:
.470²-.472² (11.93-11.99 mm)
Starter Drive Bushing Clearance:
Std: .0015²-.004² (.038-.102 mm)
Service Limit:
.008² (.203 mm)
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 90° apart to determine
if bushing is out of round. Calculate bushing
clearance. Replace bushing if clearance exceeds
the service limit.
6. Inspect gear teeth on starter drive.
starter drive if gear teeth are cracked, worn, or
broken.
FLYWHEEL/STATOR
REMOVAL/INSPECTION
1. Remove flywheel nut and washer.
2. Install Flywheel Puller (PN 2871043) and remove
flywheel. CAUTION: Do not thread the puller
bolts into the flywheel more than 1/4² 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.
A
3.32
5. Replace crankshaft seal (A).
6. Remove oil passage O-Ring (B).
Replace
7. Remove large sealing O-Ring from outer edge of
stator plate.
CAM CHAIN/TENSIONER
BLADE
A
1. Remove bolt securing tensioner blade to
crankcase (A).
B