Polaris Outlaw 500, Service Manual

Page: 192 / 202

7.19
ELECTRICAL
7
Brush Inspection / Replacement
1. Using a digital multi-tester, measure the resistance
between the cable terminal and the insulated brush. The
reading should be .3 ohms or less.
2. Measure the resistance between the cable terminal and
brush housing. Make sure the brush is not touching the case.
The reading should be infinite.
3. 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.
4. Remove brush plate and brushes. Measure length of
brushes and replace if worn past the service limit. Replace
springs if they are discolored or have inadequate tension.
5. Inspect surface of commutator for wear or discoloration.
See Steps 3–6 of armature testing on Page 7.20.
6. Install a new carbon brush assembly in the brush housing.
NOTE: Be sure that the terminal bolt insulating
washer is properly seated in the housing, and the
tab on the brush plate engages the notch in the
brush plate housing.
7. Place a wrap of electrical tape on the threads of the terminal
bolt to prevent O–Ring damage during reinstallation.
8. Install the O–Ring over the bolt. Make sure the O–ring is
fully seated.
9. Remove the electrical tape and reinstall the two small
phenolic washers, the large phenolic washer, flat washer,
and nut.
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.
Brush Length Service Limit:
5/16” (.8 cm)
Brush Set
5/16” (.8 cm)
Brush length