2009 Polaris Outlaw 450/525 Service Manual, Page 179Get this manual
ELECTRICAL 56Inspect surface of commutator for wear or discolorationSee Steps 36 under "Armature Testing"Install new carbon brush assembly in the brush housing54Measure 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 360If hacksaw blade is drawn to armature on any pole, the armature is shorted and must be replaced
NOTE: 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 housing789Place wrap of electrical tape on the threads of the terminal bolt to prevent ORing damage during reinstallationInstall the ORing over the boltMake sure the Oring is fully seatedRemove the electrical tape and reinstall the two small phenolic washers, the large phenolic washer, flat washer, and nutStarter Reassembly