Flywheel/Stator Removal/Inspection; Flywheel/Stator Installation - Polaris Sportsman 700 Efi 2005 Service Manual

FLYWHEEL/STATOR
REMOVAL/INSPECTION
1. Remove stator housing bolts and remove
housing.
2. Remove flywheel nut and washer.
3. Install Flywheel Puller (PN 2871043) and remove
flywheel (A). CAUTION: Do not thread the puller
bolts into the flywheel more than 1/4" or stator
coils may be damaged.
2871043
4. Use caution when removing the wire holddown
(B), trigger coil (C), and the stator assembly (D).
Do not tap or bump the gear /stator housing
cover or the stator. This could cause the seal
around the gear/stator housing cover and the
crankcase to break, causing a leak.
5. Remove the bendix (E) if necessary.
FLYWHEEL/STATOR
INSTALLATION
Remove
Stator Cover
NOTE:
holes with Primer N (PN 2870585) to remove any
debris. This will ensure proper sealing when installing
bolts.
1. Carefully install the stator and trigger coil to the
2. Properly place the stator wires under the wire
A
3. Install the starter bendix if removed.
4. Install woodruff key. Install the flywheel. Install
E
Before assembly, clean the bolts and bolt
gear/stator housing cover. Do not tap on the
stator or the gear stator housing cover. This
may cause a leak in between the gear/stator
housing cover and the crankcase.
holddown and install the bolts. Inspect the bolts, if
new bolts are needed, replace them with new
bolts. The new bolts contain patch lock, so
Loctitet is not needed on the new bolts. Torque
bolts to 96 ± 12 in.lbs. (10.85 ± 0.35 Nm).
the flywheel washer and nut. Torque the flywheel
nut to 65 ± 7 ft.lbs. (88 ± 9.50 Nm)
ENGINE
C
B
D
3.37