Snowmobile Arctic Cat (2007 year). Instruction - part 52

 

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Snowmobile Arctic Cat (2007 year). Instruction - part 52

 

 

5-12

4. Inspect brush leads for cracks, wear, or fraying.

If any of these conditions exist, replace with

new brushes along with new brush springs as a

set.

5. Inspect the rear cover bushing for wear. 

6. Inspect the front cover bearing for wear.

7. Inspect the brass commutator end of the arma-

ture for any discolored spots or damage. If the

commutator is slightly discolored or damaged,

the armature must be replaced. This is a molded

commutator and no attempt to turn it down in a

lathe should be attempted.

8. Inspect the commutator end of the armature for

buildup in the grooves. Carefully remove any

buildup by undercutting using a thinly ground

hacksaw blade. Do not cut any deeper than the

original groove which can be seen by looking at

the end of the commutator.

9. Using a caliper, measure the undercut. Maxi-

mum undercut groove must be 0.2 mm (0.008

in.).

SNO2171

10. Inspect the commutator for shorting using a

multimeter and the following procedure.

A. Set the selector to the OHMS position.

B. Touch the black lead to the armature shaft.

C. Using the red tester lead, probe the commuta-

tor end of the armature. The meter indicator

should not change. If the indicator shows

resistance, the armature is shorted and must

be replaced.

11. Inspect the armature for shorting using a

“growler” and the following procedure.

A. Place the armature in the “growler.”

B. While holding a metal strip on the armature,

rotate the armature an entire revolution. If the

metal strip vibrates at any point on the arma-

ture, the armature is shorted and must be

replaced.

0725-653

12. Inspect the ground brushes to make sure they are

properly grounded. Use a multimeter and the

following procedure.

A. Set the selector to the OHMS position.

B. Touch the black tester lead to a ground brush.

C. Touch the red tester lead to the brush holder

assembly.

„ NOTE: If no resistance is indicated, check the
ground connection for tightness and for cleanli-
ness. If there is still no meter indication, replace
the brush assembly. 

! CAUTION

Do not use emery cloth to clean the commutator as
emery particles will become imbedded in the brass
commutator resulting in a short circuit. Use only
#200 grit sandpaper.

! CAUTION

Buildup in the grooves must be removed to prevent
any chance of an electrical arc between individual
sections of the commutator.

5-13

5

ASSEMBLING (660 cc)

1.  Install the brushes and springs. 

AO294

„ NOTE: When installing the brushes, it is easier
to have the brush springs removed; then using a
pair of needle-nose pliers, compress the springs
and install them into the holder. 

2.  Install the armature into the commutator case.

AO289

3. Install the pinion-stop nut onto the armature

shaft making sure the lip of the nut faces inward.

Tighten securely.

AO288

4.  Install the commutator cap onto the commutator

case making sure the alignment marks made

during disassembling align.

AO287

5. Install the end cap and secure with existing

through-bolts. Tighten securely.

AO285

AO284

6. Install the pinion lever; then properly position

the solenoid onto the starter motor.

! WARNING

When installing the brush springs, wear safety
glasses.

5-14

AO283

7. Secure the solenoid to the starter motor using

existing cap screws. Tighten securely.

AO282

8. Secure the starter wire strap to the solenoid

using the existing solenoid nut. Tighten

securely.

AO281

ASSEMBLING (1100 cc Z1)

1. With the brush assembly secured in a vise, com-

press each brush all the way into the housing;

then carefully push the brush wire over and

down to secure the brush in the fully com-

pressed position.

ZJ143

„ NOTE: The brushes must be fully compressed to
allow enough room to install the armature.

2. Install the armature into the brush assembly;

then using a small needle-nose pliers, carefully

move the brush wires upward allowing the

brushes to fully contact the commutator.

ZJ145

„ NOTE: After completing step 2, ensure that the
brushes are properly seated to the commutator.

3. Noting the alignment marks made in disassem-

bling, install the magnet housing; then with the

magnet housing properly seated to the brush

assembly, install the snap ring, shim, and lock-

ing plate to the armature shaft.

„ NOTE: If alignment marks were not made during
disassembling, align properly by matching notch
on the magnet housing to notch on the brush
assembly.

5-15

5

ZJ153A

4. With a suitable driving tool, install new seal into

the bearing housing; then install the bearing

housing.

„ NOTE: Prior to installing the bearing housing,
position the locking plate with the tabs (A) of the
locking plate aligned with the cap screw ears (B) of
the starter motor.

ZJ144A

5. Install the two long cap screws securing the

starter motor together; then tighten the cap

screws to 1.0-1.4 kg-m (7-10 ft-lb).

ZJ140A

INSTALLING (660 cc)

1. Connect the starter solenoid and the starter

motor cable.

MD1700

2. Install the starter motor to the engine and secure

with the two cap screws (coated with blue Loc-

tite #243). Tighten to 1.0-1.4 kg-m (7-10 ft-lb).

MD1437

3. Install the driven pulley; then install the drive

belt.

„ NOTE: On turbo models to install these compo-
nents, proceed to ACT Roller Driven Pulley (Turbo
Models); then proceed to Removing/Installing
Drive Belt (ACT Roller Driven Pulley) in Section 8
of this manual.

INSTALLING (1100 cc Z1)

1. Install the starter motor to the engine; then with

the ground cable positioned to the top mounting

hole, install the two cap screws (B) (coated with

blue Loctite #243) and tighten to 2.8 kg-m (20

ft-lb).

ZJ139A

 

 

 

 

 

 

 

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