Polaris TRAIL BOSS 325 2001, Manual

Page: 289 / 296

ELECTRICAL
10.25
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. Replace spring. 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 that the spring is positioned between the
shoe alignment pins and the back flange of the
anti kick-out shoes.
2. Remove the lock ring, end 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.
Starter Solenoid Bench Test
It is difficult to test the high amp side of the solenoid
accurately on the bench. The only test which can be
done on the bench is the pull-in coil resistance. The
reading should be 3.4 ohms.
Polaris Premium Starter Drive Grease
PN 2871460
Starter Motor Exploded View
O-ring
Rear Brkt Assy
Armature
Set Bolt Assy
Washer
Washer Set
Rubber Rings
Weight Spring
Return Spring
Carbon
Brush
Set