Club Car Gasoline Service Manual page 165

Cleaning, Inspection, and Replacement of Brush Springs
1. Visually inspect springs. Replace all four springs if any spring is discolored from heat (straw or bluish in
color).
2. Install the four brushes (27) into their holders and insert the four brush springs (28) (Figure 12-41).
Using a spring scale, test brush spring tension. If the any spring has a tension less than 24 ounces,
replace all four springs (Figure 12-42) (See Caution below).
CAUTION
• WHEN CHECKING BRUSH SPRING TENSION, DO NOT PULL SPRINGS BEYOND THE POINT
THEY WOULD NORMALLY BE IF THERE WERE NEW BRUSHES INSTALLED. EXERTING EXCES-
SIVE FORCE OR PULLING BRUSH SPRINGS BEYOND THEIR NORMAL RESTING POINT WILL
DAMAGE SPRINGS.
REPLACE SPRINGS
WHICH APPLY A
FORCE OF LESS
THAN 24 OUNCES
Assembly of the Starter/Generator
WARNING
• WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS:
- WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION.
- REMOVE THE KEY.
- PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL.
- DISCONNECT THE BATTERY AS SHOWN (FIGURE 12-1, PAGE 12-2).
• FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED.
• SEE THE SAFETY WARNINGS ON PAGE 12-1.
1. Connect the brush wires to the holders using the four lockwashers (26) and four screws (25), making
sure the crossover leads are connected also. Apply 26-35 in.lbs. (2.9/3.9 N-m) of torque to the screws
(Figure 12-41).
2. To prevent contact between the brushes and commutator as the commutator is installed, and possible
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 12-43, Page 12-30).
FIGURE 12-42
12
G
Page 12-29