2001 Polaris Sportsman 400-500 DUSE and H.O. Service Manual, Page 355Get this manual
ELECTRICAL
STARTER MOTOR DISASSEMBLY, CONT4Remove shims from armature shaftNOTE: All shims must be replaced during reassembly
BRUSH INSPECTIONREPLACEMENT
1Using 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 tension