Polaris 2005 Sportsman MV7, Service Manual

Page: 298 / 312

ELECTRICAL
10.42
6. Place armature in a growler. Turn growler on and
position a hacksaw blade or feeler gauge
lengthwise 1/8
″
(.3 cm) above armature coil
laminates. Rotate armature 360
°
. If hacksaw
blade is drawn to armature on any pole, the
armature is shorted and must be replaced.
CAUTION:
Use care when handling starter housing. Do not drop
or strike the housing as magnet damage is possible.
If magnets are damaged, starter must be replaced.
STARTER
REASSEMBLY/INSTALLATION
1. Install brush plate to field magnet housing aligning
index tab.
2. Install O-ring, two small phenolic spacers, large
phenolic washer, flat washer, lock washer, and
terminal nut.
3. While holding brush springs away from brushes,
push brushes back and hold in place.
4. Slide armature into field magnet housing.
Release brushes.
5. Lightly grease the drive roller bearing and reinstall
drive end frame on armature. Inspect seal for
wear or damage. Replace drive end cap if
necessary.
Roller Bearing
Seal
6. Be sure wire insulation is in place around positive
brush wire and pushed completely into slot on
phenolic plate.
7. Using a non-petroleum grease, lubricate brush
end bushing and install shims.
Dielectric Grease (PN 2871329)
8. Align brush plate and install cover and screws.
9. Lightly grease pinion shaft and install pinion,
spring stopper, and snap ring.
10. Install the starter onto the engine case. Hand
tighten each of the starter bolts. Torque the
bottom bolt first to 9 ft.lbs. (12 NM) . Then
torque the top bolt to the same specification.