Arctic Cat DVX 400 2004 Service Manual page 99

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.
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 fraying. 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 turning 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 hack-
saw blade. Do not undercut any deeper than the orig-
inal 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.).
10
! 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.
C. Using the red tester lead, probe the commutator
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.
12. Inspect the ground brushes to make sure they are
properly grounded. Use a multimeter and the follow-
ing 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.
ATV-1054
0725-653