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  1. #1
    alindo01's Avatar
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    Angry Help with Starter installation!!!!

    Guys- I'm rebuilding a 2004 Polaris Freedom 700cc but this is the second time the starter bolts break off on the block with less than 9 Foot LBS. of torque (Specified in the Manual). I had to remove the whole flywheel, casing and bendix to remove the starter NOW it happened again! WTH!

    Any suggestions on removing the bolt with the starter in place so I dont have to dissassemble everything again?

    How critical is it to correct it? 1 good bolt, 1 broken...


  2. #2
    Click avatar for tech links/info, donation request K447's Avatar
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    Which starter bolt is broken - top or bottom?

    The starter motor body twists in reaction when cranking the engine. If the broken bolt is on the motor tab that is pressed against the block when the starter is cranking, you might get away with just one good bolt.

    I don't know if I would be comfortable leaving it like that, however...

    Did you clean out the threads in the block with a thread tap before installing the starter bolts?

    No metal ridges or raised corrosion spots that might be holding one or both of the starter tabs away from the block?

  3. #3
    alindo01's Avatar
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    Its the bottom bolt that broke for the second time. The engine is new (rebuilt SBT) and yes I usually go through all the threads with the tap to clean them out. I can figure out what is causing the bolt to break with less than 9 foot lbs.

  4. #4
    casey67's Avatar
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    You do not have to disassemble the front of the engine to remove the starter. The front of the starter is sealed with an O-ring, after the bolts are out,twist and pull,it will come out.

  5. #5
    alindo01's Avatar
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    Thanks guys I will try to remove again...

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