Arctic Cat DVX 400 2008 Service Manual page 96

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REMOVING/DISASSEMBLING
1. Disconnect the battery.
! CAUTION
Always disconnect the negative battery cable from
the battery first; then disconnect the positive cable.
2. Remove the nut securing the positive cable to the
starter; then remove the cable from the starter.
3. Remove the cap screws securing the starter to the
crankcase; then remove the starter.
4. For assembly purposes, scribe a line across the
outside of the starter assembly.
5. Remove the two through-bolts securing the starter
components. Account for the O-rings.
6. Remove the left-side cover from the starter hous-
ing. Account for washers and housing O-ring.
7. Remove the right-side cover. Account for washers
and housing O-ring.
8. Slide the armature free of the starter housing.
9. Remove the nut from the positive post. Account
for the lock washer, flat washer, a fiber washer,
and an O-ring.
10. Bend the two positive brushes outward; then
remove the brush holder. Account for two brush
springs and brushes.
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.
! CAUTION
Do not wash the armature and brushes in any kind
of solvent. Use only compressed air and a clean dry,
lint-free cloth.
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2. Inspect all threaded areas for damage or stripped
threads.
3. Inspect the brush holder assembly and brushes for
damage or wear. Using a caliper, measure the
length of the brushes. If brush measurement is less
than 10.1 mm (0.40 in.), replace with new brushes
and brush springs as a set.
4. Inspect the brush leads for cracks, wear, or fray-
ing. If any of these conditions exist, replace with
new brushes and brush springs as a set.
5. Inspect the left-side cover bushing for wear.
6. Inspect the right-side cover bushing for wear.
7. Inspect the brass commutator end of the armature
for any burned spots or damage. If the commutator
is lightly burned or damaged, the armature must be
replaced. This is a molded commutator and turn-
ing it down in a lathe should not be attempted.
! 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.
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 undercut 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. Maximum
undercut groove must be 0.2 mm (0.008 in.).
! CAUTION
Buildup in the grooves must be removed to prevent
any chance of an electrical arc between individual
sections of the commutator.
10. Inspect the commutator for shorting using a multi-
meter and the following procedure.
A. Set the selector to the OHMS position.
B. Touch the black lead to the armature shaft.
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