2005-2007 Polaris Ranger 500 service manual, Page 326Get this manual
ELECTRICAL 4Measure the resistance between each commutator segment and the armature shaftThe reading should be infinite (no continuity)Check commutator bars for discolorationBars discolored in pairs indicate shorted coils, requiring replacement of the starter motorPlace armature in growlerTurn growler on and position hacksaw blade or feeler gauge lengthwise 18" (.3 cm) above armature coil laminatesRotate armature 360oIf hacksaw blade is drawn to armature on any pole, the armature is shorted and must be replaced
Starter Drive
Pinion GearAnti Kick-out Shoe, Garter Spring Replacement If the garter spring is damaged, the overrun clutch may fail to return properlyThe replacement spring is (PN 7042039)Use either of the following methods to remove and install new garter spring Rear Brkt Assy Washer Set Carbon Brush SetStarter Reassembly
123Inspect permanent magnets in starter housingMake sure they are not cracked or separated from housingPlace armature in field magnet casingPlace shims on drive end of armature shaft with phenolic washer outermost on shaftEngage tabs of stationary washer in drive end housing, holding it in place with light film of greaseInstall case sealing O-RingMake sure O-Ring is in good condition and not twisted on the caseLubricate needle bearing and oil seal with light film of grease, and install housing, aligning marksInstall O-Ring on other end of field magnet casingMake sure it is in good condition and not twisted on the caseAlign casing marks and install housing, pushing back brushes while installing shaft in bushingReinstall starter motor housing set boltsMake sure ORings are in good condition and seated in groove