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10.33
ELECTRICAL
10
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
© Copyright 2010 Polaris Sales Inc.
2. Install O-ring, two small phenolic spacers, large phenolic
washer, flat washer, lock washer, and terminal nut.
3. While holding brush springs away from brushes, push
brushes back and hold in place.
4. Slide armature into field magnet housing. Release brushes.
5. Lightly grease the drive roller bearing and reinstall drive
end frame on armature. Inspect seal for wear or damage.
Replace drive end cap if necessary.
6. Be sure wire insulation is in place around positive brush
wire and pushed completely into slot on phenolic plate.
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.
10. Completely assemble 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 Drive
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:
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 the spring is positioned between the shoe
alignment pins and the back flange of the anti kick-out
shoes.
Roller Bearing
Seal
Set Bolt Torque: 35-52 in. lbs. (3.9-5.9 Nm)
A. Gear Assembly
B. Thrust Washer
C. Busing
D. Retaining Ring
E. Thrust Washer
F. Stopper
G. Cover
H. Spring
A
B
C
D
E
F
G
H