Polaris 2012 Sportsman Forest 500 International, Service Manual

Page: 406 / 432

10.42
ELECTRICAL
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
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.