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10.20 Battery and Electrical Systems 9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual © 2011 Polaris Sales Inc. Starter Motor/Flex Drive Assembly Starter Motor/Flex Drive Service The starter motor, flex drive, and pinion gear can be 1. Remove the exhaust pipe. If servicing the motor, remove the silencer. 2. When servicing the pinion gear, remove the y-pipe. 3. Using a ball-end allen wrench, remove the 3 screws attaching the pinion assembly to the engine. 4. To remove the starter motor, remove the gear clamp, and then the two-rear starter motor mount nuts. 5. During assembly, install the flex drive on to the pinion assembly. Install the three pinion assembly screws 6. Loosely fit the gear clamp around the motor, and then install the flex drive on to the motor shaft. 7. Torque the rear nuts to specification. 8. Torque the gear clamp hand tight. 9. Reinstall the y-pipe. Torque fasteners to specification. 10. Reinstall the silencer and exhaust pipe. FLEX DRIVE END PLATE MOUNTING BRACKET STARTER MOTOR PINION/PINION BRACKET WORM GEAR CLAMP A B B C CAUTION Disconnect battery before servicing starter motor components. Always remove RED(+) battery cable first, and then BLACK(-) cable. Reverse order during battery installation. = T A = 22 ft-lb (30 Nm) B = 7 ft-lb (10 Nm) C = 8 ft-lb (11 Nm) |