Starter Drive - Polaris 2004-2005 Sportsman 6x6 Service Manual

ELECTRICAL

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. The replacement spring is
(PN 7042039). Use either of the following methods to
remove and install a new garter spring.
Starter Motor Exploded View
Carbon
Washer Set Brush
Set
Armature
O-ring
Set Bolt Assy
Return 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.
10.46
2. Remove the lock ring, end washer, spring
Rear Brkt Assy
NOTES
Rubber Rings
Washer
Weight 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.
Polaris Premium Starter Drive Grease
(PN 2871460)