Starter Drive - Polaris Sportsman 700 Efi 2005 Service Manual

NOTE: It is important to tighten the bottom starter bolt
first, 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.
9 ft.lbs. (12 Nm)
Torque the bottom bolt first!
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.

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:
Gear Assembly
Thrust Washer
Bushing
Polaris Premium Starter Drive Grease
(PN 2871460)
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
Spring
Cover
Stopper
Retaining
Thrust
Ring
Washer
10.41