2009 Polaris Scrambler 500 4x4 2x4 factory service manual, Page 251Get this manual
ELECTRICAL
BRUSH INSPECTIONREPLACEMENT
Brush Set
4Inspect surface of commutator for wear or discolorationSee Steps 3-6 of armature testing on Page 10.365Install new carbon brush assembly in the brush housingNOTE: 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 housing6Place wrap of electrical tape on the threads of the terminal bolt to prevent O-Ring damage during reinstallation7Install the O-Ring over the boltMake sure the O-ring is fully seated
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 damaged