Polaris SPORTSMAN 600 2003 Service Manual page 250

ELECTRICAL ELECTRICAL
STARTER REASSEMBLY
1. Install brush plate to field magnet housing aligning
index tab.
2. Install O-ring, two small phenolic spacers, large
phenolic washer, flat washer, lock washer, and
terminal nut.
3. While holding brush springs away from brushes,
push brushes back and hold in place.
4. Slide armature into field magnet housing.
Release brushes.
5. Lightly grease the drive roller bearing and reinstall
drive end frame on armature. Inspect seal for
wear or damage.
necessary.
6. Be sure wire insulation is in place around positive
brush wire and pushed completely into slot on
phenolic plate.
10.26
Replace drive end cap if
Roller Bearing
Seal
STARTER REASSEMBLY CONT'D
7. Using a non-petroleum grease, lubricate brush
end bushing and install shims.
Dielectric Grease (PN 2871329)
8. Align brush plate and install cover and screws.
9. Lightly grease pinion shaft and install pinion,
spring stopper, and snap ring.
STARTER SOLENOID BENCH
TEST
To measure the resistance of the pull-in coil, connect
one meter lead to the Yellow/Red wire and the other
to ground. The resistance should be 2.8-3.6 ohms.
Refer to Electric Starter System Testing in this section
to further test the solenoid.