2001 Polaris Sportsman 400-500 DUSE and H.O. Service Manual, Page 359Get this manual
ELECTRICAL
STARTER DRIVE
Pinion GearAnti Kick-out Shoe, Garter Spring Replacement If the garter spring is damaged, the overrun clutch may fail to return properlyThe replacement spring is PN 7042039Use either of the following methods to remove and install new garter spring
Polaris Premium Starter Drive Grease PN 2871460
1Screw the overrun clutch out to the engaged position on the pinion shaft assemblyUse small piece of wire with the end bent in hook and pick the old spring out of its channelSlide it off the end of the shaftSlide the new spring over the overrun clutch and into the spring grooveMake sure that the spring is positioned between the shoe alignment pins and the back flange of the anti kick-out shoes2Remove the lock ring, end washer, spring retainers and clutch return springScrew the overrun clutch off the end of the pinion shaftRemove the old spring and install new oneLightly grease the pinion shaft and reinstall the clutch, spring, retainers, end washer and lock ring in the reverse orderMake sure the end washer is positioned properly so that it will hold the lock ring in its grooveStarter Solenoid Bench Test It is difficult to test the high amp side of the solenoid accurately on the benchThe only test which can be done on the bench is the pull-in coil resistanceThe reading should be 3.4 ohms