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post #11 of 21 (permalink) Old 05-30-2012, 03:38 AM Thread Starter
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This bushing is not brass, so not sure if a tap will work
I'm going to fleet today and talk with my buddy mechanics, so I can get several opinions on remova
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post #12 of 21 (permalink) Old 05-30-2012, 04:33 AM
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"Easy Outs" are for broken bolts. Types of metal shouldnt matter... it should do the trick but ask your buddy.
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post #13 of 21 (permalink) Old 05-31-2012, 01:47 PM Thread Starter
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Well removed the bushing with a chisel, took about 15 minutes tops. The bushing material will just break up at a certain point and fall out of the bore

I don't recommend this procedure because you can gouge the bore the bushing presses into

now just waiting on my new bushings to arrive, then off to install it and button up this polaris
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post #14 of 21 (permalink) Old 06-07-2012, 03:46 PM Thread Starter
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update
I got it put back together, new bushing and the correct starter bendix drive

however I got a strange starting issue now and will start another thread for that
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post #15 of 21 (permalink) Old 08-24-2019, 05:17 PM
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case side bendix bushing

2002 Sportsman 500 DUSE. Bendix is making a LOT of noise when the quad is running. I know the case side busing is worn due to bendix just floating around inside of it. However; New bushing seems to be slightly smaller.. Is this normal or am I missing something? I have not pulled the old bushing out, I only held the new on top of the old to compare size..

I dont dare to remove "old one" whereas I can at least start it with the current set up. Please advise!
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post #16 of 21 (permalink) Old 08-24-2019, 05:31 PM
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Pictures if it helps!
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post #17 of 21 (permalink) Old 08-24-2019, 07:30 PM
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Here's the crankcase bushing 3083669. The one you have looks too small. Does it fit the end of the Bendix?
Polaris sure is proud of them at $21 a pop. Here's a link

https://www.ebay.com/itm/NEW-GENUINE...YAAOSw2s1cf-By
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post #18 of 21 (permalink) Old 08-25-2019, 07:23 AM
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Quote:
Originally Posted by jschlip1990 View Post
2002 Sportsman 500 DUSE. Bendix is making a LOT of noise when the quad is running. I know the case side busing is worn due to bendix just floating around inside of it. However; New bushing seems to be slightly smaller.. Is this normal or am I missing something? I have not pulled the old bushing out, I only held the new on top of the old to compare size..

I dont dare to remove "old one" whereas I can at least start it with the current set up. Please advise!
Where did you get the bushing in the pics? The part number polman provided is correct for both the bushing in the recoil cover as well as the engine case. If the bushing you have came from Polaris, what is the part number you got?

Bushings come in various standard sizes both metric and inch. You might be able to get a bushing from a local bearing supplier and simply cut it to length. I can buy 8x10x10 mm bronze bushings from an industrial supply out of Chicago for less than $3 each with no minimum purchase requirement. If I were working on it and only needed one bushing, I would get it from Polaris. If you got the bushing you have from Polaris and it's part number 3083669, then it's possible the engine was repaired with a custom bushing. If that's the case, you just need to extract the bushing and take it to a local machine shop and have them manufacture a replacement.

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post #19 of 21 (permalink) Old 08-26-2019, 05:52 AM
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The bushing fits both sides of the bendix. It also fits very well into the recoil housing. The bushing came with a new recoil kit that I purchased due to a broke spring and cracked case. Perhaps this bushing is smaller to fit the new housing and different than the case side. However: I would assume not. How can I get the bushing out of the case side without destroying it so that I can compare it to a new Polaris bushing?

On second thought, and zooming in on the picture... Is the very front of that a taper or bevelled to help the bushing slide in.. If that's the case, maybe the bushing is the correct size... SMH
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post #20 of 21 (permalink) Old 08-26-2019, 07:47 AM
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Did you purchase the recoil kit part number 3087163 from Polaris?

The hole for the bushing has a bevel to ease installation - the bushing can be removed with a small internal blind hole bearing puller, but they are specialized and expensive - the easiest removal method is to tap threads into the bushing (destroying the bushing) and then running a flat end bolt in to push against the case which in turn lifts the bushing out of the hole. Heating the case to about 300 degrees F makes extraction easy (very little force is needed).

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