Dec. 13, 2005 - - Polaris conducted a conference call yesterday with dealers to discuss potential failures in starter gears on the new FS and FST models. The problems were found on a product line check. This failure was also found in five models that were in consumers' hands, though Polaris says there's a high likelihood of the part failing during the life of the machine.
Dealers were told that starter gear teeth can be stripped, since engine backfire ads excess load to the starter gear on these machines. The problem can begin at initial startup, during a rough idle and stall situation, when the vehicle runs out of gas or during severe cold starting. The result is a machine that won't start.
Polaris says the starter gear failure is caused by changes implemented by the engine supplier - the two-piece starter gear was changed to one piece and the support bushing from the housing cover was changed. Polaris was not notified of the changes.
What happens is the one-piece gear can be stripped when it's not able to withstand a backfire load, or a tooth can be chipped on the gear when an incorrect bushing is used.
Polaris plans to have dealers replace the parts with the two-piece gear and the correct support bushing as a warranty item where Polaris will cover 100% of the parts and labor charges. Parts will be shipped to dealers shortly, and consumers should contact their dealers to set up service. Polaris says it will also send a $50 gas card directly to affected consumers within 3 weeks.
More info:
www.polarisindustries.com