1985-1995 Polaris ATV and Light Utility Hauler Service Manual, Page 394Get this manual
ELECTRICAL Magnum Starter System 4Remove shims from armature shaftNOTE: All shims must be replaced during reassembly
Brush InspectionReplacement
Using digital multitester, measure the resistance between the cable terminal and the insulated brushThe reading should be .3 ohms or lessMeasure the resistance between the cable terminal and brush housingMake sure the brush is not touching the caseThe reading should be infinite2Remove nut, flat washer, large phenolic washer, two small phenolic washers, and O-Ring from brush terminalInspect the O-Ring and replace if damaged3Remove brush plate and brushesMeasure length of brushes and replace if worn past the service limitReplace springs if they are discolored or have inadequate tension1Install new carbon brush assembly in the brush housingNOTE: Be sure that the terminal bolt insulating washer is properly seated in the housing, and the tab on the brush plate engages the notch in the brush plate housing5Place wrap of electrical tape on the threads of the terminal bolt to prevent O-Ring damage during reinstallation6Install the O-Ring over the boltMake sure the O-ring is fully seated7Remove the electrical tape and reinstall the two small phenolic washers, the large phenolic washer, flat washer, and nut