Club Car Carryall 500 2015 Maintenance And Service Manual page 333

SECTION 20 — ELECTRICAL COMPONENTS: PEDAL-START
GAS VEHICLE
DANGER
Electrical Components: Pedal-Start Gas Vehicle
• See General Warnings on page 1-1.
WARNING
• See General Warnings on page 1-1.
STARTER/GENERATOR
See General Warnings on page 1-1.
TESTING THE STARTER/GENERATOR
See Test Procedure 12 – Starter/Generator (Starter Function) on page 18-32.
See Test Procedure 11 – Starter/Generator (Generator Function) on page 18-32.
STARTER/GENERATOR REMOVAL
1. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section
1, Page 1-4.
2. Place the neutral lockout switch in the MAINTENANCE position. Access the engine compartment by removing
the seat or raising the cargo bed.
3. Disconnect the wires from the starter/generator (1) (Figure 20-13, Page 20-12).
4. Loosen the pivot nuts (7) and bolts (5) (Figure 20-12, Page 20-11).
5. Remove the adjustment nut (4), washer (6) and adjustment bolt (1) (Figure 20-12, Page 20-11). Lower the
starter/generator and remove the belt (2) from the pulley.
6. Support the starter/generator so that when the pivot bolts (5) are removed the starter/generator will not fall.
Remove the two pivot nuts (7) and bolts (5) from the mounting bracket.
7. Remove the starter/generator.
DISASSEMBLY OF THE STARTER/GENERATOR TO SERVICE THE BRUSHES
1. Remove the two bolts (20) and pull commutator end cover (23) free of starter/generator housing (24) (Figure
20-1, Page 20-2). See following NOTE.
NOTE: 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. 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 20-5, Page 20-4).
2. Remove brush covers (29 and 30), terminal hardware (25), brush springs (28), and brushes (27) (Figure 20-2,
Page 20-2). See following NOTE.
NOTE: To clean and inspect the armature/commutator and the bearings, see Disassembly of the Starter/Generator
to Service the Armature/Commutator on page 20-4.
2015 Carryall 500 and 700 Maintenance and Service Manual
20
Page 20-1