I have a 2008 Polaris Sportsman 800. We are attempting (waiting on parts) to replace the water pump seal, oil seal and the shaft bearing in the oil pump area. The service manual suggest removing the stator housing which includes removing the flywheel.
We attempted to remove the flywheel by using a harmonic balancer on the outer ring to keep from damaging any teeth. Well, the outer ring popped off and we didn't have it marked. We finally got the fly wheel off, but mine is now in two pieces. I work in sales at a hydraulic repair shop so we have the tools and know-how to press this back on but..........How do we line this back up

 

The three 8mm bolt holes on the center of the flywheel are what you are what you are supposed to pull it off,not a jaw type puller.I've heard of this happening before,but hasn't happened to me. Unless you find an alignment mark,the gap on the ring gear is supposed to be timed to the crank position sensor. Ring gear doesn't show to be sold separately. Hopefully someone else had done this and can chime in if they've found a way to do this.

 

we did find some marks on the flywheel itself (see pic below) and there is an arrow on the outer ring. We were wondering what they were and if this is suppose to be lined up with each other

 

Those are the flywheel ignition advance and retard marks and with the "F" firing mark and "T" for tdc.

 

Bad news!! These are installed at the factory only. There is nothing in any Polaris Sportsman manual that will fix this. I have to buy a new flywheel. The Polaris technician at our local dealership is good friends with several people that I know. Its a goner!!!
Now, if I buy a new one, will it automatically be set up like the old one? We marked the aluminum housing where the arrow on the ring gear was. If I install it the same way that the old one came off......will I be okay?

 

New flywheel will have the ring gear preset at the proper location,with the gap in the teeth timed for the crank position sensor.