Starter Drive Removal/Inspection - Polaris Trail Boss 330 2003 Service Manual

ENGINE
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:
.4735²-.4740² (11.11-12.04 mm)
Std. Shaft OD:
.470²-.472² (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.
3.26
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.
A
4. Remove bolts and carefully remove stator
assembly, being careful not to damage crankshaft
bushing on stator plate.
Starter Drive Bushing Clearance:
Std: .0015²-.004² (.038-.102 mm)
Service Limit:
008² (.203 mm)
A
Replace