Fly Wheel Key - Is It Removable on the 04 Polaris 800?

[go high fast]

Is this key removable?

The assembly instructions in the Polaris Shop Manual reference the key being removed and the flywheel being reinstalled with key AND locktight on the 500/600 small block motors but NO mention of either on the 700/800 big block motors. Also from the photos in the Shop Manual they show pictures of the big block crank with the key apparantly still in place and NOT removed???

I've started to slightly damage the key thinking it was removable but dont want to totally trash it at this point.

Any advice??

THANKS

 

[alsled]

The key comes out, I use a screwdriver under the lip and knock it up and out, then put a piece of sandpaper on a flat surface and rub key on it to remove any burrs

 

[go high fast]

The little bugger is definately NOT coming out. I have already tried "a bigger hammer" multiple times.....I dont have a sledge hammer.

This may be the first time in a long time I may have to surrender to dealer assistance.....despicable!!!

One other option is to remove the stator to have a bit more room to get at it and also to throw some heat at it. Actually at this point I'm convinced that no amount of banging or prying will get it removed.

It almost looks like someone used JB Weld on it.

 

[diggerdown]

Someone may have used some loctite on it, I don't know why they would but usually they come out without too much fuss. I take it you plan on putting in a new or advanced timing key. I'd pull the staor and put some heat to it, if it has red or green loctite you need it hot. Put a cold wet rag around the crank in front of the seal to protect it from the heat. The quicker you can heat it up the less heat saturation up the crank, so use the hottest torch you have. If you don't have a cutting torch use mapp instead of propane.

 

[rocket]

Polaris' shop manual recommends setting those parts (flywheel, key, retaining nut) with "permanent" grade loctite, so what you see isn't totally surprising. Sometimes the keys don't like to move easy (better tight than loose), though I've never had one that wouldn't come out.