2005 Polaris Sportsman 400/500 Service Manual, Page 91Get this manual
ENGINE 5Replace crankshaft seal (A)StdBushing ID: .4735 -.4740 (11.11-12.04 mm) StdShaft OD: .470 -.472 (11.93-11.99 mm) B
Starter Drive Bushing Clearance: Std: .0015 -.004 (.038-.102 mm) Service Limit: .008 (.203 mm) 4Measure the OD of the starter drive shaft on both ends and record5Measure the ID of the bushing in the recoil housing (A) and in the crankcase and recordMeasure in two directions 90 apart to determine if bushing is out of roundCalculate bushing clearanceReplace bushing if clearance exceeds the service limit6Inspect gear teeth on starter driveReplace starter drive if gear teeth are cracked, worn, or broken