Starter Installation; Starter Drive - Polaris Sportsman 800 EFI 4x4 2012 Service Manual

Starter Installation

1. Install the starter onto the engine case. Hand tighten
each of the starter
specification.
Starter Retaining Bolts:
9 ft-lbs (12 Nm)
Torque bottom bolt first, then torque top bolt.
NOTE: It is important to tighten the bottom
starter bolt first (circle), as the bottom hole acts
as a pilot hole to properly align the starter drive
(bendix) with the flywheel. This helps to prevent
binding and starter damage.
2. Reconnect the battery cable going to the starter.
3. Reconnect the battery.
bolts. Torque bolts to
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.

Starter Drive

Pinion Gear - Anti-kick Out Shoe, Garter Spring
Replacement
If the garter spring is damaged, the overrun clutch may
fail to return properly. Use either of the following methods
to remove and install a new garter spring:
1. Screw the overrun clutch out to the engaged position
on the pinion shaft assembly. Use a small piece of
wire with the end bent in a hook and pick the old
spring out of its channel. Slide it off the end of the
shaft. Slide the new spring over the overrun clutch
and into the spring groove. Make sure that the spring
is positioned between the shoe alignment pins and
the back flange of the anti kick-out shoes.
2. Remove the retaining ring, thrust washer, spring
retainers and clutch return spring. Screw the overrun
clutch off the end of the pinion shaft. Remove the old
spring and install a new one. Lightly grease the
pinion shaft and reinstall the clutch, spring, retainers,
end washer and lock ring in the reverse order. Make
sure the end washer is positioned properly so that it
will hold the lock ring in its groove.
ELECTRICAL
10
10.45