Polaris Ranger 500 2x4 2007, Service Manual

Page: 327 / 345

10.41
ELECTRICAL
10
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 360o. If
hacksaw blade is drawn to armature on any pole, the
armature is shorted and must be replaced.
Starter Reassembly
1. Inspect permanent magnets in starter housing. Make sure
they are not cracked or separated from housing.
2. Place armature in field magnet casing.
3. 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.
4. 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.
5. Install O-Ring on other end of field magnet casing. Make
sure it is in good condition and not twisted on the case.
6. Align casing marks and install housing, pushing back
brushes while installing shaft in bushing.
7. Reinstall starter motor housing set bolts. Make sure O-
Rings are in good condition and seated in groove.
Starter Drive
Pinion Gear - Anti Kick-out Shoe, Garter Spring Replacement
If the garter spring is damaged, the overrun clutch may fail to
return properly. The replacement spring is (PN 7042039). Use
either of the following methods to remove and install a new
garter spring
1. Screw the overrun clutch out to the engaged position on the
pinion shaft assembly. Use a small piece of wire with the
end bent in a hook and pick the old spring out of its
channel. Slide it off the end of the shaft. Slide the new
spring over the overrun clutch and into the spring groove.
Make sure that the spring is positioned between the shoe
alignment pins and the back flange of the anti kick-out
shoes.
2. Remove the lock ring, end washer, spring retainers and
clutch return spring. Screw the overrun clutch off the end
of the pinion shaft. Remove the old spring and install a new
one. Lightly grease the pinion shaft and reinstall the clutch,
spring, retainers, end washer and lock ring in the reverse
order. Make sure the end washer is positioned properly so
that it will hold the lock ring in its groove
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.
Set Bolt Torque: 35-52 in. lbs. (3.9-5.9 Nm)
Polaris Premium Starter Drive Grease
(PN 2871460)
Washer Set
Armature
O-ring
Set Bolt Assy
Weight Spring
Return spring
Rubber Rings
Washer
Rear Brkt Assy
Carbon
Brush
Set
35-52 in. lbs.
(3.9-5.9 Nm)