starter crankcase bushing destroyed - Polaris ATV Forum
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post #1 of 14 (permalink) Old 05-28-2012, 06:09 PM Thread Starter
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starter crankcase bushing destroyed

here is some pics of my 2007 polaris Trail Boss 330 starter crankcase bushing destroyed, and the pieces are stuck to the pick up coil ( I think it's called) you can also see where the gear was grinding into the casing

I corrected one problem a few days ago (no start condition) and yet another appears.The engine acted like it was hard to turn over today

I have been having a grinding noise coming from the recoil housing, when trying to start the polaris. I removed the recoil housing to discover the bendix was hanging up and not retracting off the fly wheel ring gear. I removed the bendix to inspect it, and discovered this other issue, a destroyed starter crankcase bushing

I think the bendix spring has been weaken from the binding and now will not snap back in place quickly. I will replace it, however the bushing is another issue
What is the best way to remove this bushing and will it be easy to find another bushing for replacement>
thanks for your time
[IMG]The engine acted like it was hard to turn over today[/IMG]


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post #2 of 14 (permalink) Old 05-29-2012, 06:31 AM
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Don't know if you can get a L shape behind that and use a slide hammer to pull it. Might also try a Pilot Bearing puller. In a pinch, I have used a tap to cut threads in a blind bearing like that and if you can keep turning it, it will push the worn bearing out or at least give you enough threads to use a bolt to pry it out. Necessity is the mother of invention.

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post #3 of 14 (permalink) Old 05-29-2012, 06:44 AM
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Quote:
Originally Posted by fmartin_gila View Post
. In a pinch, I have used a tap to cut threads in a blind bearing like that and if you can keep turning it, it will push the worn bearing out or at least give you enough threads to use a bolt to pry it out. Necessity is the mother of invention.

Fred
Right on the money! I replaced mine and used a tap to do it! Just make sure that the tap that your using is not pointy on the tip. If so it will crack the crank case. I used a grinder to flatten the tip of the tap and it worked great, just use a little lube and you'll be fine!

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post #4 of 14 (permalink) Old 05-29-2012, 12:35 PM
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I had an old guy show me how to remove this style bushing by packing it full of grease and using a bolt the same size as the opening. Once it's full of grease insert the bolt and smack it with a hammer. most usually pop right out. I've used this trick for years.

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post #5 of 14 (permalink) Old 05-29-2012, 05:28 PM Thread Starter
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Quote:
Originally Posted by RENOBADBOY View Post
I had an old guy show me how to remove this style bushing by packing it full of grease and using a bolt the same size as the opening. Once it's full of grease insert the bolt and smack it with a hammer. most usually pop right out. I've used this trick for years.
thanks for the input
I have used this trick myself, however I'm concerned about the aluminum casing, it may fracture or worse, using this method
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post #6 of 14 (permalink) Old 05-29-2012, 05:30 PM Thread Starter
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Quote:
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Quote:
Originally Posted by fmartin_gila View Post
. In a pinch, I have used a tap to cut threads in a blind bearing like that and if you can keep turning it, it will push the worn bearing out or at least give you enough threads to use a bolt to pry it out. Necessity is the mother of invention.

Fred
Right on the money! I replaced mine and used a tap to do it! Just make sure that the tap that your using is not pointy on the tip. If so it will crack the crank case. I used a grinder to flatten the tip of the tap and it worked great, just use a little lube and you'll be fine!
thanks for the info
not sure how your removal techniques work, however something to consider
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post #7 of 14 (permalink) Old 05-29-2012, 05:34 PM Thread Starter
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Quote:
Originally Posted by fmartin_gila View Post
Don't know if you can get a L shape behind that and use a slide hammer to pull it. Might also try a Pilot Bearing puller. In a pinch, I have used a tap to cut threads in a blind bearing like that and if you can keep turning it, it will push the worn bearing out or at least give you enough threads to use a bolt to pry it out. Necessity is the mother of invention.

Fred
thanks for the info
sounds like several good ideas , I'm still thinking on how to approach this with the lease damage to crankcase
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post #8 of 14 (permalink) Old 05-29-2012, 05:36 PM Thread Starter
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the blind bearing removal tool is not cheap. so going to scrap that idea for now
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post #9 of 14 (permalink) Old 05-29-2012, 05:57 PM
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Maybe a modified easy out tool? Since there reverse threaded. You could use a hack saw and cut it down to fit...cheap solution maybe
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post #10 of 14 (permalink) Old 05-29-2012, 06:28 PM
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Quote:
Originally Posted by fmartin_gila View Post
Might also try a Pilot Bearing puller.
Fred
I have this same issue with my 500. The Bendix bushing is cracked. It is not as bad as the one in the picture. I couldn't figure out how to get the bushing out so I greased it up and put a very thin stainless washer over the Bendix shaft to act as a thrust washer and put it back together. I would really like to fix it properly. How does a pilot bearing puller work?

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