Polaris 2007 Sportsman 450 EFI, Service Manual

Page: 366 / 406

10.48
ELECTRICAL
Starter Reassembly
1. Inspect permanent magnets in starter housing. Make sure
they are not cracked or separated from housing. Place
armature in field magnet casing.
2. Place shims on drive end of armature shaft with phenolic
washer outermost on shaft. Engage tabs of stationary
washer in drive end housing, holding it in place with a light
film of grease.
3. Install case sealing O-Ring. Make sure O-Ring is in good
condition and not twisted on the case. Lubricate needle
bearing and oil seal with a light film of grease, and install
housing, aligning marks.
4. Install O-Ring on other end of field magnet casing. Make
sure it is in good condition and not twisted on the case.
5. Align casing marks and install housing, pushing back
brushes while installing shaft in bushing.
6. Reinstall starter motor housing bolts. Make sure O-Rings
are in good condition and seated in groove.
7. Align brush plate and install cover and screws.
8. Install the starter onto the engine case. Hand tighten the
starter bolt.
Torque the bolt to 9 ft.lbs. (12 Nm ).
Starter Solenoid Bench Test
To measure the resistance of the pull-in coil, connect one meter
lead to the solenoid lead wire and the other to ground. The
resistance should be 3.7 ohms
± 5 %
.
Refer to “Electric Starter
System Testing” in this section to further test the solenoid.
Starter Exploded View
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.