Starter Drive; Starter Assembly - Polaris SPORTSMAN 400 2003 Service Manual

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.

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
Brush
Washer Set
Set
Armature
O-ring
Set Bolt Assy
Return Spring
ELECTRICAL
Rear Brkt Assy
Rubber Rings
Washer
Weight Spring
10.25