Polaris SPORTSMAN 400 2003, Service Manual

Page: 263 / 274

ELECTRICAL
10.24
5. 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.
6. Place a wrap of electrical tape on the threads of
the terminal bolt to prevent O-Ring damage
during reinstallation.
7. Install the O-Ring over the bolt. Make sure the
O-ring is fully seated.
8. 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.
3. Using a digital multitester, measure the
resistance between each of the commutator
segments. The reading should be .3 ohms or
less.
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 360 . If hacksaw
blade is drawn to armature on any pole, the
armature is shorted and must be replaced.
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