Starter Solenoid Bench Test; Starter Drive - Polaris RANGER XP 700 4X4 Service Manual

ELECTRICAL
7. Using Dielectric Grease (PN 2871329), lubricate brush end
bushing and install shims.
8. Align brush plate and install cover and screws.
9. Lightly grease pinion shaft and install pinion, spring
stopper, and snap ring.
Set Bolt Torque: 35-52 in. lbs. (3.9-5.9 Nm)
10. Completely assembly starter motor and torque set bolts to
35 - 52 in. lbs. (3.9 - 5.9 Nm).
11. Install the starter onto the engine case. Hand tighten each
of the starter bolts. Torque the bottom bolt first to 9 ft.lbs.
(12 Nm). Then torque the top bolt to the same specification.
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.

Starter Solenoid Bench Test

To measure the resistance of the pull-in coil, connect one meter
lead to the solenoid lead wire and the other to ground. The
resistance should be 2.8 - 3.6 ohms. Refer to "Electric Starter
System Testing" in this section to further test the solenoid.
10.36

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:
A
B
A. Gear Assembly
B. Thrust Washer
C. Busing
D. Retaining Ring
E. Thrust Washer
F. Stopper
G. Cover
H. 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.
H
G
F
D
E
C