Club Car FE350 2005 Maintenance Service Supplement page 80

12
ELECTRICAL COMPONENTS
Starter/Generator Assembly, Continued:
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CAUTION
• To prevent damage to the retainer, use care while pressing new bearing onto the output end of
the shaft.
• Press against the inner race of the new bearing until it is fully seated.
6. Install the output end cover (36) onto the armature. Secure the bearing retainer (32) to the cover and
tighten the screws (43) to 39 in-lb (4.4 N·m) (Figure 12-7, Page 12-5).
7. Slide the housing with field coils over the armature. Use the locating pin to align housing to the cover.
NOTE: The terminal insulators should be on the commutator end of the housing.
8. To prevent contact between the brushes and commutator as the commutator cover is installed, and pos-
sible 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).
9. Install the commutator end cover (23) onto the armature shaft. Align the locating pin with the pin hole in
the cover. Install the two M6 x 180 mm bolts (20), and tighten to 100 in-lb (11.3 N·m) (Figure 12-2,
Page 12-2).
10. Push the brushes down into the holders. Place 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 covers
(29) in the openings in the commutator end cover (23) (Figure 12-3, Page 12-2).
11. Slide the spacer (37) onto the end of the shaft. Insert the shaft key (34) into the shaft. Install the belt pulley
(39) onto the shaft, and install the lock washer (40) and M14 nut (41). Tighten the nut to 28 ft-lb
(38.0 N·m) (Figure 12-7, Page 12-5).
Starter/Generator Installation
1. Install the green wire from the F1 terminal to the A1 terminal on the starter/generator (Figure 12-1,
Page 12-1). Install a flat washer, lock washer, and nut onto each terminal and tighten to 48 in-lb (5.4
N·m).
2. Install two 3/8-inch hex-head pivot bolts (5) into the mounting bracket with the heads of the bolts facing
toward the driver-side of the vehicle. Position the starter/generator in the mounting bracket so that the
bolts will go through the starter/generator before going through the bracket. Install a lock nut (7) onto
each bolt. Tighten to finger tight (Figure 12-13, Page 12-11).
3. Install the adjustment bolt (11) through the adjusting bracket (4) and then through the starter/generator.
Install a lock washer (9) and 5/16-inch nut (12) onto the end of the adjustment bolt (11). Tighten to finger
tight (Figure 12-13, Page 12-11).
4. Install the belt (3), then tighten the mounting bolts. See Belt Tension Adjustment on page 12-11.
5. Connect the yellow wire from the voltage regulator to the DF terminal on the starter/generator. Install a
flat washer, lock washer, and nut onto the terminal. Tighten the nut to 31 in-lb (3.5 N·m).
6. Install the white wire from the solenoid to the F2 terminal on the starter/generator. Install the black wire
from the frame to the A2 terminal on the starter/generator. Install a flat washer, lock washer and nut onto
each terminal, and tighten the nut to 48 in-lb (5.4 N·m).
7. Connect battery cables, positive (+) cable first, and tighten hardware to 12 ft-lb (16 N·m).
See Figure 10-1, Section 10, Page 10-3. Coat terminals with Battery Terminal Protector Spray (CCI P/
N 1014305) to minimize corrosion.
Page 12-10 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement
Starter/Generator