Snowmobile Arctic Cat 2-Stroke (2007 year). Instruction - part 74

 

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Snowmobile Arctic Cat 2-Stroke (2007 year). Instruction - part 74

 

 

5-26

DISASSEMBLING

„NOTE: For assembly purposes, scribe a refer-
ence line on the end plate/drive cap, commutator
cap, and the case.

1. If applicable, remove the snap ring securing the

primary gear to the starter motor; then remove the

gear and account for the spring washer.

2. Remove the two long through-bolts. As the bolts

are being removed, hold pressure against the com-

mutator cap.

AI050

3. Slowly remove the cap and account for the four

brush holder springs.

AI026

4. Using a plastic hammer, tap the end plate/drive

cap free of the starter case and slide the cap free

from the armature shaft. Account for any washers.

AI027

5. Slide the armature free of the starter case.

AI028

6. Lift all brushes from the brush holder and account

for the four brush springs.

7. Using a 5/16-in. socket, remove the two cap

screws securing the ground brushes to the commu-

tator cap. Remove the brushes and brush holder

from the cap.

AI036

8. Using a 7/16-in. wrench, remove the nut securing

the cable stud to the cap. Account for the number

of and the position of washers.

AI037

9. While holding the brush wires, pull the stud from

the end cap. Account for the plastic insulator.

5

5-27

CLEANING AND INSPECTING

„NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Thoroughly clean all components except the arma-

ture and brushes in parts-cleaning solvent; then

dry with compressed air.

AI029

2. Inspect all threaded areas for damaged or stripped

threads.

3. Inspect the brush holder assembly and brushes for

damage or wear. Using a calipers, measure the

length of the brushes. If brush measurement is less

than 7.5 mm (0.30 in.), replace brushes as a set

along with new brush springs.

AI030

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

any of these conditions exist, replace the brushes

as a set along with new brush springs.

5. Inspect the commutator cap bushing for wear.

Using a calipers, measure inner diameter at the cap

bushing. If found to be 8.6 mm (0.338 in.) or

larger, replace the cap.

AI031

6. Inspect the end plate/drive cap bushing for wear.

Using a calipers, measure the inner diameter of the

cap bushing. If found to be 13.2 mm (0.523 in.) or

larger, replace the cap.

AI032

7. Inspect the brass commutator end of the armature

for any burned spots or damage. If the commutator

is slightly burned or damaged, the armature must

be replaced. This is a molded commutator and no

attempt to turn it down in a lathe should be tried.

8. Inspect the commutator for buildup in the grooves.

Buildup in the grooves must be removed to pre-

vent any chance of arcing between individual sec-

tions of the commutator. Carefully remove any

buildup using a thinly ground hacksaw blade. Do

not cut any deeper than the original groove which

can be seen by looking at the commutator from the

side.

! WARNING

When using compressed air to dry components,
always wear safety glasses.

! CAUTION

Do not wash the armature and brushes in any kind
of solvent. Use only compressed air and clean dry
cloth in cleaning these components.

! 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 #00
grit sandpaper.

5-28

AI033

„NOTE: After cleaning any buildup from the com-
mutator, use compressed air to clean.

9. Inspect the armature for shorting. Use the multit-

ester and the following procedure:

A. Set the selector on the OHMS position; then

touch the leads and zero the meter.

B. Touch the black tester lead to the armature

shaft.

C. Using the red tester lead, probe the commutator

end of the armature. The meter indicator should

not move. If the indicator needle moves, the

armature must be replaced.

AI034

10. Inspect the armature for shorting. Use a “growler”

and the following procedure:

A. Place the armature in the “growler.”

B. While holding a metal strip over 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

11. Inspect the ground brushes to make sure they are

properly grounded. Use the multitester and the fol-

lowing procedure:

A. Set the selector on the OHMS position; then

touch the leads and zero the meter.

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

C. Touch the red tester lead to the commutator

cap. The meter needle should move to the right.

If the needle does not move to the right, check

that the ground connection is tight and clean.

Recheck for proper ground. If there still isn't

any meter needle movement, replace the

brushes as a set along with new brush springs.

AI035

ASSEMBLING

1. Install the stud with the positive brush set attached

in the commutator cap. Make sure the insulator is

in position over the stud and the longest brush lead

is positioned to the right of the stud hole.

5

5-29

AI038

2. In order from disassembling, place the washers on

the stud. Apply a small amount of red Loctite #271

to the stud threads and secure with the nut. Tighten

to 0.7 kg-m (5 ft-lb).

AI039

3. Place the brush holder into position in the commu-

tator cap.

„NOTE: Position the longest positive brush lead
beneath the ground wire on right side.

4. Place a cap screw through the left ground brush

lead eyelet and position the eyelet flat against the

brush holder. Secure with a cap screw.

5. Place the right ground brush eyelet flat against the

brush holder and secure with a cap screw. The eye-

let stem must be positioned to the top of the

threaded hole boss in the commutator cap.

AI040

6. Place the four brush springs into the brush holder

and place each brush (flat side down) on top of the

springs.

„NOTE: Apply a small amount of low-temperature
grease to the cap bushings.

7. Place a wave washer and a thrust washer on the

armature shaft; then slide the front cap into posi-

tion.

8. Apply a thin coat of grease to the armature shaft

and slide the drive gear and spring washer onto the

shaft. Secure with a snap ring.

9. Start the commutator end of the armature assem-

bly into the starter case at the end with the fields

nearest the end of the housing. Align the marks on

the front cap and case.

AI042

10. Compress the four brushes (flat side down) into

the brush holder. Hold the brushes in position

using the Starter Assembly Tool (p/n 0644-052).

! CAUTION

Check the stud to make sure insulator is between
stud and cap on backside.

 

 

 

 

 

 

 

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