Polaris 1999 Sportsman 400 Service Manual page 327

ELECTRICAL SYSTE:l.1
321
2. Measur e the leng th of eac h brush (Fig ure 3 1).1 1'
the length is equal to or less than the limi t in Ta ble
I. replace the bru shes as a se t,
3. Inspect the bru sh s pr ings for dam age or weak-
ness . Replace the spr ings if necessary.
4. Inspect the co m m utator (F ig ure 32) . Th e mica
should be be low the surface of the copper com mu ta-
tor segments (Figu re 33). If the com mutator seg-
ments are worn to the same level as the mica
insulation, have the co m mut ator serviced
by
a
deal er or elec trica l repair shop.
5. Inspect the co mm utato r copper seg ments for d is-
coloration. If the commutator segments are rough,
discol ored or worn, have the commu tator serv iced
III
at a Po laris dealership or electrica l repair shop.
6. Usc an ohm me ter to perform the following:
a . C heck for co ntinuity betw een the com muta-
tor bar s (Figu re 34 ); there sho uld be co ntinu-
ity bet ween pairs of ba rs.
b. Ch eck for continuity between the commuta-
tor bars and the shaft (Fig ure 35 ); there
should be
11 0
contin uity (infi nite res istance).
c. If the unit fails either of these tests. the starter
asse m bly m us t be rep lace d. The arma ture
cannot be replaced individually.
7. Inspect the bear ing and seal (Fi gure 36 ) in the
front cover for wear or da ma ge.
8. Inspect the bushing ( Figure 37) in the rear cover
for wear or damage .
9. Inspect the starte r hou
sin g (A,
Figure 38) for
cracks or ot he r damage .
10. Inspect inside the
starter housing for loose,
chipped or damaged magnets (B, Figure 38).
II . Inspe ct the sta rter hou sin g G-ri ngs (F ig ure 39 )
for deterioration. flat s pots or other damage. Re-
place them as required .