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ELECTRICAL
Starter System
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.
Starter Assembly
1.
Place armature in field magnet casing.
2.
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.
3.
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.
4.
Install O-Ring on other end of field magnet casing.
Make sure it is in good condition and not twisted on
the case.
5.
Align casing marks and install housing, pushing
back brushes while installing shaft in bushing.
6.
Reinstall starter motor housing bolts.
EH42PL, EHSOPL:
Make sure O-Rings are in good condition and seated in groove.
EC38PL, EC28PF, EC2SPF:
Install new gasket on starter flange.
7.
Inspect permanent magnets in starter housing. Make sure they are not cracked or separated from housing.
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.
7/96
10.30
Polaris Industries Inc.
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Troubleshooting
