Club Car FE350 2005 Maintenance Service Supplement page 74

12
ELECTRICAL COMPONENTS
Starter/Generator Assembly
1. Connect the brush wires to the holders using four lock washers (26) and four screws (25), making sure
the crossover leads are connected also. Tighten the screws to 31 in-lb (3.5 N·m) (Figure 12-3,
Page 12-2).
2. To prevent contact between the brushes and commutator as the commutator is installed, and possible
damage to the brushes, lift the brush springs out of the notches in the brushes and pull the brushes back
from the center of the commutator end cover. The springs will rest on the sides of the brushes and help
prevent them from sliding towards the center of the cover (Figure 12-6, Page 12-4).
3. Install the commutator end cover (23) onto the armature shaft. Align the locating pin with the pin hole in
the cover. Install two M6 x 180 mm bolts (20) and tighten to 100 in-lb (11.3 N·m) (Figure 12-2,
Page 12-2).
4. Push the brushes down into the holders. Position springs into the notches in the brushes. Install the
brush cover (30) that has the drain hole in it next to the A2 terminal. Install the remaining three brush cov-
ers (29) in the openings in the commutator end cover (23) (Figure 12-3, Page 12-2).
Disassembly of the Starter/Generator to Service the Armature/Commutator
1. If the brushes are not removed, contact between the brushes and commutator as the commutator end
cover is being removed or installed could damage the brushes.
1.1. Lift the brush springs out of the notches in the brushes and pull the brushes back from the center
of the commutator end cover. The springs will rest on the sides of the brushes and help prevent
them from sliding towards the center of the cover (Figure 12-6, Page 12-4).
2. Remove the two bolts (20), and pull commutator end cover (23) free of the starter/generator housing (24)
(Figure 12-2, Page 12-2).
3. To separate armature (33) from output end cover (36), remove nut (41), lock washer (40), pulley (39),
shaft key (34), spacer (37), and bearing retainer screws (43) (Figure 12-7, Page 12-5).
Page 12-4 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement
Figure 12-6 Pull Brushes Away from Center of the Commutator End Cover
BRUSH BEING HELD
BY BRUSH SPRING
Starter/Generator