Electric Starting Motor Inspection - Arctic Cat Cougar Service Manual

ELECTRICAL SYSTEM
if
necessary, before removing the bendix
assembly in Step 2.
2. Remove the stopper (19, Figure 45), spring
(18, Figure 45) and pinion gear (17, Figure 45)
from the end of the starter motor.
3. Mark the end cap (7, Figure 45), housing (12,
Figure 45) and front cover (16, Figure 45) so
they can be easily aligned when assembling.
4. Support the starter on the end cap (7, Figure
45) in an upright position and loosen the two
through bolts (21, Figure 45).
5. Support the starter and remove the 2 through
bolts.
CAUTION
Be careful not to lose thrust washers,
springs or other small parts when disas-
sembling. Some parts may be propelled
by spring pressure when parts are sepa-
rated.
6. Remove the end cap (7, Figure 45), brush
holder (8, Figure 45) and brushes (1 0, Figure
45). Be careful not to lose the brush springs (11,
Figure 45).
CAUTION
One or more washers (14, Figure 45)
may be located on the nose of the arma-
ture shaft. The washer( s) may stick to the
front cover or may stay on the armature
shaft. Account for washer( s) when disas-
sembling.
291
7. Tap the front cover ( 16, Figure 45) with a
soft-faced hammer if necessary to separate it
from the center housing.
Inspection
1. Clean all grease, dirt and carbon from the
armature, case and end covers.
CAUTION
Do not immerse the armature in solvent
that would damage its insulation. Wipe
the windings with a clean, dry cloth, then
blow with low pressure compressed air.
2. Check threaded parts and bushings for wear
or damage. Replace as necessary.
3. Measure the inside diameter of the bushing in
end cap (7, Figure 45). Replace the end cap if
the bushing is larger than 8.6 mm (0.339 in.)
(Figure 46).
4. Measure the inside diameter of the bushing in
the front cap ( 16, Figure 45) and replace the
front cap if the bushing is larger than 13.2 mm
(0.520 in.).
5. Measure the length of the brushes ( 10, Figure
45). Replace all of the brushes if any of them are
shorter than 7.6 mm (0.30 in.) (Figure 47).
6. Check the brushes for chips, cracks or frayed
wires. Replace as necessary.
7. Inspect the commutator end of the armature
(13, Figure 45). If the commutator is rough,
burned or otherwise damaged, replace the arma-
ture. Do not attempt to repair the commutator.
8. Inspect the grooves in the commutator for
built-up dirt. You can clean the commutator
grooves using a hacksaw blade ground to the
original width of the groove. Do not attempt to
cut the groove deeper than the original depth.
9. Use an ohmmeter to check for continuity
between the commutator bars and the armature
shaft. Any evidence of continuity indicates a
short to ground and that the armature should be
replaced.