2007 Polaris Sportsman 700/800/800 X2 EFI Service Manual, Page 360Get this manual
ELECTRICAL Brush Replacement 1Remove terminal nut with lock washer, flat washer, large phenolic washer, the small phenolic spacers, and sealing O-ringInspect O-ring and replace if damaged4Measure the resistance between each commutator segment and the armature shaftThe reading should be infinite (no continuity)Slide positive brush springs to the side, pull brushes out of their guides and remove brush plate
CAUTION
Some cleaning solvents may damage the insulation in the starterCare should be exercised when selecting an appropriate solventIf the commutator needs cleaning use only electrical contact cleaner5Check 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 360'If hacksaw blade is drawn to armature on any pole, the armature is shorted and must be replacedArmature Testing