1985-1995 Polaris ATV and Light Utility Hauler Service Manual, Page 391Get this manual
ELECTRICAL
Starter Motor Static Testing Remove starter motorDisassemble, clean and inspect brushesNOTE: Some cleaning solvents may damage the insulation in the starterCare should be taken when selecting an appropriate solventThe brushes must slide freely in the brush holders and firmly contact the commutatorIf the commutator needs cleaning, use only an electrical contact cleaner andor non-metallic grit sandpaperReplace the brush assembly when the brushes are worn to 516" (.8 cm) or lessStarter Housing and Field Magnet Inspection Using digital multitester, measure the resistance between the starter input terminal and the insulated brushesThe reading should be .3 ohms or lessMeasure the resistance between the input terminal and the starter housing with the brushes not touching the frameThe reading should be infiniteInspect the permanent magnets in the starter housing to be sure they are not cracked and have not separated from the housingCAUTION: Use care when handling the starter housingNever drop or strike the housing with hard object as magnet damage is possibleAny damage to the field magnets will require replacement of the starter assemblyArmature Testing Using digital multitester, measure the resistance between each of the segments of the commutatorThe reading should indicate .3 ohms or lessMeasure the resistance between the commutator and armature shaftThe reading should be infinitePlace the armature in growlerWith the growler on, position hack saw blade lengthwise 18" (.3 cm) above the armature coil laminatesRotate the armature 360 If the hacksaw blade is drawn to the armature on any pole the armature is shorted and must be replaced