Starter Drive Gear Polaris Virage I 2002

[fbsmith]

Has anyone changed the starter drive gear on a polaris viragei 2002? Can you tell me what components need to be removed and can it be done with the engine in? My starter just spins so I removed it and felt that there is a tooth or two missing on the gear I can turn it and then replace starter and start ski but eventually it lands in the flat spot again and the starter just spins. Any help would be appreciated. It is a completly stock ski.

[Keddano]

Here you go.

1.) Start by removing (2) 8mm bolts holding the oil pump, located on the front of the Stator housing.Pull the oil pump out of the way,Do not remove the hoses.

2.) Remove (7) 10mm bolts holding the stator cover to the engine side housing. (The cover is located by 2 locating dowels,pry the cover off straight!)
(be careful not to drop the spring and plastic insert that applies pressure to the starter bendix nose. It fits in a boss on the inside of the cover.)

3.)The bendix will pull out,(may have to wiggle it a little)

4.)Clean mating surfaces of all old gasket,and install new gasket reassemble.

Check your teeth on your flywheel. More then likely it's just that the bendix is hanging up and not locking. Sometimes you can oil them up and they will work. But with the PIA to open it up,just put a new one in.This can be done without removing the Gas Tank.

[K447]

...there is a tooth or two missing on the gear I can turn it and then replace starter and start ski but eventually it lands in the flat spot again and the starter just spins...

Is the tooth missing from the large ring gear around the perimeter of the flywheel, or the smaller gear that the starter motor connects through?

[fbsmith]

Thanks for the information I will give it a try in the morning so from my understanding the flywheel does not need to be removed? Thanks again.
Fred

[fbsmith]

I beleive it is where the starter connects that is what i feel from where the starter goes in.

[Keddano]

I don't think you'll find any teeth missing. Once you get it apart,post pictures if your unsure . The gear on the starter is always engaged into the bendix,so it would be almost impossible to strip a tooth there.

[fbsmith]

I will post a pic if it is a tooth missing but from what i understand from your post is the gear will spin becasue it is not engauging the bendix. That is probably the problem. The only thing I am not real clear on is the flywheel does it need to be removed to get the bendix out?

[Keddano]

No,The flywheel can stay on. So that's a big Plus and a PIA to get off.

[Bernie]

My advice ,If you have any peices of material that have come off the bendix drive or the starter drive remove the front cover and also the flywheel and clean it out properly .The peices will eventually be attracted to the flywheel magnets and destroy the flywheel and stator assy .Generally whilst you are from the shore and on your own.I had this happen after my local dealer changed the starter and about 6 months later I found the peices in the flywheel .Don't be slack fix it right the first time or you will pay for it later

Bernie

[Keddano]

Good advise Bernie,Hadn't thought of that.

[fbsmith]

I got the water jacket cover and the stator cover off the bendix came out of its position as i was trying to remove it but I cannot figure out how to get it past the flywheel does the round plastic cover that covers im guessing the stator or flywheel have to come off?

[K447]

You have downloaded the Service manual, via the Tech section - correct?

[fbsmith]

Yes thanks im looking at the manual but it is a little unclear in this area according to the manual the flywheel needs to come out but previous advice here says no im sure there is a way to wiggle it around just have not figured it out yet.

[Bernie]

You have to remove the flywheel to get it out .

Bernie

[Keddano]

FBSSmith, Maybe it does have to come off,I thought it would make it past it. My bad. I swore i've done it on the bench.Maybe old age. Here's a link showing how to modify a puller to fit without pulling the gas tank.
When you pull the flywheel,try and watch that you don't lose the half moon key,If you don't see it check the magnets on the flywheel,it normally catches it.

http://www.greenhulk.net/showthread.php?t=52187