Starter Assembly - Polaris Sportsman 400 Service Manual

ELECTRICAL

STARTER ASSEMBLY

1. Place armature in field magnet casing.
2. Place shims on drive end of armature shaft with
phenolic washer outermost on shaft. Engage tabs
of stationary washer in drive end housing, holding it
in place with a light film of grease.
3. Install case sealing O-Ring. Make sure O-Ring is
in good condition and not twisted on the case.
Lubricate needle bearing and oil seal with a light
film of grease, and install housing, aligning marks.
4. Install O-Ring on other end of field magnet casing.
Make sure it is in good condition and not twisted on
the case.
5. Align casing marks and install housing, pushing
back brushes while installing shaft in bushing.
6. Reinstall starter motor housing bolts.
Make sure O-Rings are in good condition and seated in groove.
7. Inspect permanent magnets in starter housing. Make sure they are not cracked or separated from housing.
CAUTION:
Use care when handling starter housing. Do not drop or strike the housing as magnet damage is possible. If
magnets are damaged, starter must be replaced.
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