Polaris 2009 Ranger RZR 800 EFI, Manual

Page: 321 / 332

10.27
ELECTRICAL
10
Brush Replacement
1. Remove terminal nut with lock washer, flat washer, large
phenolic washer, the small phenolic spacers, and sealing
O-ring. Inspect O-ring and replace if damaged.
2. Slide positive brush springs to the side, pull brushes out of
their guides and remove brush plate.
Armature Testing
1. Remove armature from starter casing. Note order of shims
on drive end for reassembly.
2. Inspect surface of commutator. Replace if excessively
worn or damaged.
3. Using a digital multitester, measure the resistance between
each of the commutator segments. The reading should be
.3 ohms or less.
4. Measure the resistance between each commutator segment
and the armature shaft. The reading should be infinite (no
continuity).
5. Check commutator bars for discoloration. Bars discolored
in pairs indicate shorted coils, requiring replacement of the
starter motor.
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.
Starter Reassembly / Installation
1. Install brush plate to field magnet housing aligning index
tab.
CAUTION
Some cleaning solvents may damage the
insulation in the starter. Care should be
exercised when selecting an appropriate
solvent. If the commutator needs cleaning use
only electrical contact cleaner.
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.