Polaris SPORTSMAN 400 2003, Service Manual, Page: 262 / 274

ELECTRICAL
10.23
2. Remove the two bolts, washers, and sealing
O-Rings. Inspect O-Rings and replace if damaged.
3. Remove brush terminal end of housing while
holding other two sections together.
4. Remove shims from armature shaft. NOTE: All
shims must be replaced during reassembly.
BRUSH
INSPECTION/REPLACEMENT
Brush Set
1. Using a digital multitester, measure the
resistance between the cable terminal and the
insulated brush. 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.
Brush Length
5/16 (.8 cm)
Brush Length Service Limit:
5/16 (.8 cm)
3. 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.
4. Inspect surface of commutator for wear or
discoloration. See Steps 3-6 of armature testing
on Page 10.24.
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