2009 Polaris Outlaw 450/525 Service Manual, Page 178Get this manual
ELECTRICAL Starter Motor Disassembly
Use only electrical contact cleaner to clean starter motor partsSome solvents may leave residue or damage internal parts and insulation1Note the alignment marks on both ends of the starter motor casingThese marks must align during reassembly
Brush InspectionReplacement
Brush Set
Using digital multi-tester, 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 infiniteRemove nut, flat washer, large phenolic washer, two small phenolic washers, and ORing from brush terminalInspect the ORing and replace if damaged