2008 Polaris Sportsman 500 EFI/X2/Touring/500 H.O. Service Manual, Page 368Get this manual
ELECTRICAL Starter Reassembly CAUTION
Use care when handling starter housingDo not drop or strike the housing as magnet damage is possibleIf magnets are damaged, starter must be replaced1Inspect permanent magnets in starter housingMake sure they are not cracked or separated from housingPlace armature in field magnet casingPlace shims on drive end of armature shaft with phenolic washer outermost on shaftEngage tabs of stationary washer in drive end housing, holding it in place with light film of greaseInstall case sealing O-RingMake sure O-Ring is in good condition and not twisted on the caseLubricate needle bearing and oil seal with light film of grease, and install housing, aligning marksInstall O-Ring on other end of field magnet casingMake sure it is in good condition and not twisted on the caseAlign casing marks and install housing, pushing back brushes while installing shaft in bushingReinstall starter motor housing boltsMake sure O-Rings are in good condition and seated in grooveAlign brush plate and install cover and screwsInstall the starter onto the engine caseHand tighten the starter boltTorque the bolt to ft.lbs(12 Nm)