Polaris 2012 Sportsman Forest 500 International, Service Manual

Page: 404 / 432

10.40
ELECTRICAL
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Starter Motor Removal / Disassembly
NOTE: Use electrical contact cleaner to clean starter
motor parts. Some solvents may leave a residue or
damage internal parts and insulation.
1. Remove the starter from the engine.
2. Remove the two bolts, washers, and sealing O-Rings.
Inspect O-Rings and replace if damaged.
NOTE: Note the alignment marks on both ends of
the starter motor casing. These marks must align
during reassembly.
3. Remove the rear brush housing assembly, holding the
front housing and armature assembly together.
4. Remove the shims from the armature shaft and
inspect the O-rings located on the armature housing.
NOTE: The shims must be reinstalled during
reassembly.
Brush Inspection / Replacement
1. Measure resistance between starter input terminal
and insulated brushes. The reading should be .3
ohms or less. Measure the resistance between the
cable terminal and brush housing. Make sure the
brush is not touching the case. The reading should
be infinite.
2. Remove nut, flat washer, large phenolic washer, two
small phenolic washers, and O-Ring from brush
terminal. Inspect the O-Ring and replace if damaged.
O-Rings
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.
O-Rings
Shims