2009-2010 Polaris RZR Factory Service Manual, Page 349Get this manual
ELECTRICAL 2345Install 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 NOTE: 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
Starter Drive
If the garter spring is damaged, the overrun clutch may fail to return properlyUse either of the following methods to remove and install new garter spring: 6789Be sure wire insulation is in place around positive brush wire and pushed completely into slot on phenolic plateUsing Dielectric Grease (PN 2871329), lubricate brush end bushing and install shimsAlign brush plate and install cover and screwsLightly grease pinion shaft and install pinion, spring stopper, and snap ringA AGear Assembly BThrust Washer CBusing DRetaining Ring EThrust Washer FStopper GCover HSpring 110Completely assemble starter motor and torque set bolts to 3552 inlbs(3.95.9 Nm)11Install 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 specificationE