Length: 11:43
Created: May 12, 2023
What’s up, guys? Today we’re going to be showing you how to remove a flywheel on this Polaris Razer XP 1000 using the Super ATV flywheel removal tool. So, let’s get right to it.
The first thing you’re going to do is go ahead and remove your passenger side wheel and tire. Next, you’re going to want to go ahead and remove your shock. I always like to remove my hardware on the nut side, so I always put my impact on the nut. It’s just easier on the hardware and easier on the shock bushings. Now we’re going to remove our sway bar link. Now we’re going to lift up on the trailing arm and remove our bolt from our shock. Finally, we’re just going to grab our shock and move it right out of the way.
Now we need to disconnect the wiring harness connected to the stator cover. If you’re looking at your cover, move your hand right to here, then follow this wire all the way back and disconnect it. Reach right back here on this motor mount tube to find the harness. The harness will have a connector, and you’ll need to lift up on the tab and then pull the plug apart. This tab right here is what you’re lifting up on. I just use my fingers to pull it up, then grab the connector right here and pull it right out.
Next, come to the top of the stator cover and find this sensor. Follow the wiring for the sensor all the way around until it comes to this connector right here attached to the transmission. The connector will be laying on the transmission. Push down on this tab right here, then push the connector together and push down on the tab. Now we need to remove all of the hardware securing the stator cover to the engine. Once all the hardware is removed from the stator cover, you can remove the cover. A lot of times these covers are pretty stuck. Sometimes you can pull them off by hand, but often you’ll have to use a pry bar. There’s a tab right here on top where you can try to take a pry bar, rest it against the engine block, and pry out. Be careful not to pry too much on the block or the cover to avoid damaging the mating surfaces. Once it’s started, wiggle and pull straight off. Finally, grab the wiring harness that we unplugged earlier.
Now that we have our stator cover removed and out of the way, the first thing you’re going to do is remove the torque limit gear pin. If your pin stayed with the stator cover when you removed it, just grab and wiggle it out. Next, remove the torque limit gear. Then, remove the flywheel bolt from the flywheel.
It’s time to grab the Super ATV flywheel removal tool. One thing to keep in mind is that the threads are left-hand threads, matching the threads on the flywheel. Take this tool, thread it on as far as it’ll go, and snug it up a little bit. Tighten the bolt to pull the flywheel off of the crankshaft. Thread the tool onto the flywheel, then grab an adjustable wrench and snug it down just a little bit. Tighten the bolt on the flywheel removal tool to pull the flywheel off the crank. As you can see, it came off easily.
Now that the flywheel is removed from the engine, clean up the gasket surface. Use a razor blade to scrape off any excess gasket material, keeping the blade flat. Wipe down the surface with brake cleaner to ensure it’s as clean as possible. With the gasket surface cleaned, reinstall the flywheel. Notice the keyway on the flywheel and line it up with the keyway on the crankshaft. Slide it around until the keyway lines up and snaps into place.
Reinstall the flywheel bolt and torque it to 129 foot-pounds. To torque the bolt, you’ll need the flywheel holder tool from Polaris. This tool wraps around the flywheel, allowing you to get a torque wrench on it. Although we are using an impact wrench today, we recommend against this as it can potentially break the bolt off into the crankshaft. After torquing the bolt, line up the torque limit gear with the starter gear and install the torque limit pin.
Apply a dab of silicone on the two locations where the engine cases mesh together, right above the dial pin and on the other section where they mesh together. If you didn’t tear the gasket when removing the stator cover and it’s still in good shape, you can reuse it. Otherwise, purchase a new OEM gasket from Polaris. Clean the surface thoroughly and reinstall the new gasket. Carefully install the stator cover back onto the engine, ensuring not to get your fingers caught as it draws in. Give it a few good taps and make sure the bolt holes are lined up. Reinstall all the hardware for the stator cover.
Once all the hardware is started, double-check to ensure everything is straight. Use a socket with an extension to give a few good turns before running them in. Run everything up, but don’t tighten it with an impact wrench. Use a ratchet to fully tighten the hardware and torque it to the OEM Polaris specification. Reconnect the sensor harness, route it back to its original position, and plug it back into the connector.
Now, grab your shock and reinstall it along with the shock hardware. Ensure the big washer is on the side not directly touching the sway bar, and the flat washer is on the nut side. Fully tighten the hardware on both the shock and the sway bar link.
Lastly, reinstall the wheel and tire. Once you’ve fully tightened all your hardware and torqued everything to factory specs, you’re done.
That’s all there is to it to use Super ATV’s flywheel removal tool on this Polaris Razer XP 1000. Be sure to check the description below to pick yours up today. While you’re there, drop a like, comment, and subscribe. Thanks for watching, and we’ll catch you on the next one.
