3
9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual
© Copyright Polaris Industries Inc.
3.95
4. Reassemble starter one-way clutch and gear using
the following illustration.
w
Torque Limit Gear
Pin
y
Flywheel
e
Starter Gear
u
One-Way Clutch Asm
r
Screws
i
Torque Limit Gear
Asm
t
Bolt
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.
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 bolt
q
. Using a
commercially available strap wrench , hold flywheel
and torque the retaining bolt to specification.
NOTE
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), loosen 180°, retorque to 133 ft-
lb (180 Nm)
7. Wipe off excess Loctite and let stand for 1 hour
before starting engine.
NOTE
Loctite cures with time, the longer the unit is let stand
before engine starting the better the bond will be.
8. Install the starter torque limit gear
w
as an assembly.
9. Proceed to Stator Cover Installation page 3.96.
ENGINE / COOLING SYSTEM
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