Arctic Cat DVX 400 2006 Manual page 105

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5. Remove the two through-bolts securing the
starter components. Account for the O-rings.
6. Remove the left-side cover from the starter
housing. Account for washers and housing
O-ring.
7. Remove the right-side cover. Account for wash-
ers 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
armature 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 fray-
ing. If any of these conditions exist, replace with
new brushes and brush springs as a set.
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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 arma-
ture for any burned spots or damage. If the com-
mutator 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
hacksaw blade. Do not undercut any deeper than
the original groove which can be seen by look-
ing at the end of the commutator.
9. Using a caliper, measure the undercut. Maxi-
mum 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
multimeter 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 commuta-
tor end of the armature. The meter indicator
should not change. If the indicator shows
resistance, the armature is shorted and must
be replaced.
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