2007 Polaris Sportsman 700/800/800 X2 EFI Service Manual, Page 361Get this manual
ELECTRICAL Starter ReassemblyInstallation
1Install brush plate to field magnet housing aligning index tab9Lightly grease pinion shaft and install pinion, spring stopper, and snap ring
Install O-ring, two small phenolic spacers, large phenolic washer, flat washer, lock washer, and terminal nutWhile holding brush springs away from brushes, push brushes back and hold in placeSlide armature into field magnet housingRelease brushesLightly grease the drive roller bearing and reinstall drive end frame on armatureInspect seal for wear or damageReplace drive end cap if necessaryRoller Bearing Seal
10Install the starter onto the engine caseHand tighten each of the starter boltsTorque the bottom bolt first to ft.lbs(12 Nm)Then torque the top bolt to the same specificationNOTE: It is important to tighten the bottom starter bolt first (circle), as the bottom hole acts as pilot hole to properly align the starter drive (bendix) with the flywheelThis helps to prevent binding and starter damage