Starter Reassembly; Starter One-Way Clutch Inspection - Polaris Outlaw 500 Service Manual

ELECTRICAL
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
hacksaw blade is drawn to armature on any pole, the
armature is shorted and must be replaced.

Starter Reassembly

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.
1. Inspect permanent magnets in starter housing. Make sure
they are not cracked or separated from housing.
2. Reinstall starter motor housing bolts. Make sure O–Rings
are in good condition and seated in groove.
3. Place armature in field magnet casing.
4. 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.
5. 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.
7.20
CAUTION
6. Install O–Ring on other end of field magnet casing. Make
sure it is in good condition and not twisted on the case.
7. Align casing marks and install housing, pushing back
brushes while installing shaft in bushing.

Starter One-Way Clutch Inspection

o
. If
1. Inspect the drive gear teeth, bearings and thrust surfaces
for excessive wear or damage.
2. Inspect the one way drive clutch rollers and springs for
excessive wear or damage.
3. Proper function can be determined by rotating the drive
gear counterclockwise, which will engage the one-way
clutch rollers and turn the flywheel. During engine rotation,
there should be no chattering or hanging of the drive gear
and one-way clutch. Should this occur, replace one or both
components and retest. Refer to Chapter 3 for the proper
torque specifications and assembly procedures.
Flywheel
One - way Clutch
Drive Gear
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