Electric Starting Motor Assembly - Arctic Cat Cougar Service Manual

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10. Clean the pinion gear in solvent and dry
throroughly.
11. Check the pinion gear for cracks, chips, deep
scoring, excessive wear or heat discoloration.
12. Check the armature shaft spiral gear for
cracks, chips, excessive wear or heat discolora-
tion.
13. Slide the pinion gear onto the armature shaft
and work the gear back and forth by hand. The
gear should move smoothly with no sign of
roughness or binding.
14. Check the pinion spring for wear, damage or
fatigue.
15. Replace worn or damaged parts as required.
Assembly
1.
Clamp the armature in a soft-jawed vise with
the drive end up.
2. Apply a small amount of grease in the bush-
ing located in the front cover (16, Figure 45).
3. Place the shim washer (14, Figure 45) or
washers that were removed over the armature
shaft.
4. Install the front cover ( 16, Figure 45) over the
armature shaft.
5. Apply a light coat of lubriplate to the arma-
ture shaft. Install the pinion gear ( 17, Figure 45).
6. Install the spring and stopper (18 and 19,
Figure 45).
7. Install the nut (20, Figure 45) and tighten to
19-22 N.m (14-16 ft.-lb.) torque.
8. Remove the armature from the vise. Install
the housing (12, Figure 45) over the armature.
9. Assemble the brushes in the brush holder (8,
Figure 45) as follows.
a. Install the positive terminal ( 6, Figure 45)
through the end cover. Tum the terminal so
the longer brush lead is to the right when
viewing into the end cap with the stud at the
top. Make sure the insulator is installed onto
the terminal.
CHAPTER NINE
b. Install washers onto the positive terminal in
the following order: Special washer, flat
washer and lockwasher.
c. Apply a small amount of Loctite 271 (red)
to the threads of the terminal, then install
the nut. Tighten the nut to 7 N.m (5 ft.-lb.)
torque.
d. Insert the brush holder in the end cap.
e. Install the ground brush to the left, as
viewed into the end cap with the stud on the
top, and secure the lead with the screw.
f. Install the ground brush to the right, as
viewed into the end cap with the stud on the
top, and secure the lead with the screw. The
longer positive brush lead should be behind,
or under, the ground wire.
10. Apply a small amount of grease in the bush-
ing located in the end cap (7, Figure 45).
11. Insert the four brush springs into the brush
holder, then position the four brushes against the
springs with the flat side against the spring.
12. Position the end cap and brushes on a bench
with the brush holder side up.
13. Press the brushes into the pockets in the
holder with special tool (part No. 0644-052) or
equivalent, then hold the brushes in position.
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