3.36
ENGINE
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Crankcase Disassembly
NOTE: The recoil starter, starter motor, starter drive,
flywheel, stator, cam chain and sprockets can be
serviced with the engine in the frame.
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.
5. Measure the ID of the bushing in the recoil housing (A)
and in the crankcase and record. Measure in two
directions 90
o
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. Replace starter
drive if gear teeth are cracked, worn, or broken.
Flywheel and 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 1/4" 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.
5. Replace crankshaft seal (B).
6. Remove oil passage O-Ring (C).
Std. Bushing ID:
.4735”-.4740” (11.11-12.04 mm)
Std. Shaft OD:
.470”-.472” (11.93-11.99 mm)
Starter Drive Bushing Clearance:
Std: .0015”-.004” (.038-.102 mm)
Service Limit:
.008” (.203 mm)
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