Snowmobile Arctic Cat (2004 year). Manual - part 68

5-39

AI030

4. Inspect brush leads for cracks, wear, or fraying. If

any of these conditions exist, replace the brushes
as a set along with new brush springs.

5. Inspect the commutator cap bushing for wear.

Using a calipers, measure inner diameter at the cap
bushing. If found to be 8.6 mm (0.338 in.) or
larger, replace the cap.

AI031

6. Inspect the end plate/drive cap bushing for wear.

Using a calipers, measure the inner diameter of the
cap bushing. If found to be 13.2 mm (0.523 in.) or
larger, replace the cap.

AI032

7. Inspect the brass commutator end of the armature

for any burned spots or damage. If the commutator
is slightly burned or damaged, the armature must
be replaced. This is a molded commutator and no
attempt to turn it down in a lathe should be tried.

8. Inspect the commutator for buildup in the grooves.

Buildup in the grooves must be removed to
prevent any chance of arcing between individual
sections of the commutator. Carefully remove any
buildup using a thinly ground hacksaw blade. Do
not cut any deeper than the original groove which
can be seen by looking at the commutator from the
side.

AI033

NOTE: After cleaning any buildup from the com-

mutator, use compressed air to clean.

9. Inspect the armature for shorting. Use the

multitester and the following procedure:

A. Set the selector on the X1K position; then touch

the leads and zero the meter.

B. Touch the black tester lead to the armature

shaft.

C. Using the red tester lead, probe the commutator

end of the armature. The meter indicator should
not move. If the indicator needle moves, the
armature must be replaced.

AI034

10. Inspect the armature for shorting. Use a “growler”

and the following procedure:

A. Place the armature in the “growler.”

! 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 #00 grit sandpaper.

5-40

B. While holding a metal strip over the armature,

rotate the armature an entire revolution. If the
metal strip vibrates at any point on the
armature, the armature is shorted and must be
replaced.

0725-653

11. Inspect the ground brushes to make sure they are

properly grounded. Use the multitester and the
following procedure:

A. Set the selector on the X1K position; then touch

the leads and zero the meter.

B. Touch the black tester lead to a ground brush.

C. Touch the red tester lead to the commutator

cap. The meter needle should move to the right.
If the needle does not move to the right, check
that the ground connection is tight and clean.
Recheck for proper ground. If there still isn't
any meter needle movement, replace the
brushes as a set along with new brush springs.

AI035

ASSEMBLING

1. Install the stud with the positive brush set attached

in the commutator cap. Make sure the insulator is
in position over the stud and the longest brush lead
is positioned to the right of the stud hole.

AI038

2. In order from disassembling, place the washers on

the stud. Apply a small amount of red Loctite #271
to the stud threads and secure with the nut. Tighten
to 0.7 kg-m (5 ft-lb).

AI039

3. Place the brush holder into position in the

commutator cap.

NOTE: Position the longest positive brush lead

beneath the ground wire on right side.

4. Place a cap screw through the left ground brush

lead eyelet and position the eyelet flat against the
brush holder. Secure with a cap screw.

5. Place the right ground brush eyelet flat against the

brush holder and secure with a cap screw. The
eyelet stem must be positioned to the top of the
threaded hole boss in the commutator cap.

! CAUTION

Check the stud to make sure insulator is
between stud and cap on backside.

5-41

AI040

6. Place the four brush springs into the brush holder

and place each brush (flat side down) on top of the
springs.

NOTE: Apply a small amount of low-temperature

grease to the cap bushings.

7. Place a wave washer and a thrust washer on the

armature shaft; then slide the front cap into
position.

8. Apply a thin coat of grease to the armature shaft

and slide the drive gear and spring washer onto the
shaft. Secure with a snap ring.

9. Start the commutator end of the armature

assembly into the starter case at the end with the
fields nearest the end of the housing. Align the
marks on the front cap and case.

AI042

10. Compress the four brushes (flat side down) into

the brush holder. Hold the brushes in position
using the Starter Assembly Tool (p/n 0644-052).

AI043

11. Carefully place the starter case and armature

assembly into the commutator cap. Again, check
to make sure the scribed marks of these two
components are aligned. With the case flat on the
assembly tool, slowly pull the tool from the starter
motor. The case should then drop into place.

AI044

12. Apply red Loctite #271 to the threads of the two

through-bolts; then install and secure the bolts.
Tighten to 1-1.4 kg-m (7-10 ft-lb).

NOTE: The starter shouldn’t be picked up until

the two through-bolts have been secured. Spring
pressure from the brush springs will push the
commutator cap off the case.

DISASSEMBLING PINION

1. Remove the dust cap from the end of the pinion

drive by first pulling straight out and then twisting
the dust cap to the side.

2. Place a 11 mm or a 7/16 in. socket over the end of

the pinion shaft and tap the socket gently with a
hammer.

NOTE: This procedure will dislodge the snap-

ring retainer and expose the snap ring.

3. Using a side cutter, diagonal cutter, or suitable

pliers, remove and discard the snap ring.

4. Remove the snap-ring retainer (note end-for-end

orientation), pinion spring, spring retainer, and
pinion gear. Retain all components.

5-42

CLEANING AND INSPECTING
PINION

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Using parts-cleaning solvent, wash grease from

the pinion gear. Dry with compressed air.

2. Inspect the pinion gear for wear. If the gear is

worn or chipped, replace the pinion assembly.

3. Inspect the inner gear and housing. If the gear

shows any signs of wear, replace the pinion
assembly.

4. Inspect the inner housing for tightness and cracks.

If the housing shows any signs of being loose or
cracked, replace the pinion assembly.

5. Inspect the pinion return spring for wear. If the

spring shows any worn areas, replace the spring.

ASSEMBLING/INSTALLING PINION

1. Slide the pinion gear, spring retainer, pinion

spring, and snap-ring retainer (note end-for-end
orientation) onto the shaft in their original
positions.

2. Place new Snap Ring (p/n 0645-384) over the end

of the pinion shaft; then slide the snap ring over
the shaft. Using a 11 mm or 7/16 in. socket and a
hammer, gently tap the snap ring into the groove
on the shaft.

3. Apply Pinion Grease (p/n 1056-072) over the

pinion spring area.

4. Slide the dust cover over the pinion assembly

being careful not to dislodge the grease. Firmly
push the dust cover until it snaps into its retaining
groove.

TESTING STARTER MOTOR

NOTE: Before installing the starter motor, per-

form test to ensure proper operation using the fol-
lowing procedure.

1. Attach a black jumper cable to a good ground on

the starter.

2. Attach the opposite end of the black jumper cable

to the negative post of a good 12V battery.

3. Attach the red jumper cable to the positive post of

the battery.

4. Holding the starter firmly down on a work bench,

touch the red jumper cable to the positive cable
stud of the starter.

NOTE: Starter motor must instantly spin at a

high RPM. The pinion must snap out against the
stopper. If the motor does not spin, remove the red
cable immediately. Check the battery condition
and all connections. If everything checks out satis-
factorily and the starter does not spin, disassem-
ble the motor and check for pinched or broken
wires.

INSTALLING (370/440 cc Models)

1. Place the starter motor into the bracket; then

secure with existing hardware. Tighten to 1.7-2.1
kg-m (12-15 ft-lb).

2. Attach the red positive cable to the positive stud

terminal and secure with a nut and washers. While
tightening the nut, hold the cable in position so it
is parallel with the starter.

3. Secure the positive cable to the starter motor with

a long cable tie.

4. Connect the cable to the positive post of the

battery; then connect the negative cable to the
negative post.

5. Install the drive clutch.

6. Install the expansion chamber.

INSTALLING (570 cc/Pantera
Models)

1. Install the flex-drive shaft onto the starter motor

and secure with the two Allen-head screws.

2. Place the starter motor into the bracket assembly;

then secure with existing hardware. Tighten to 2.4
kg-m (17 ft-lb).

3. Attach the red positive cable to the positive stud

terminal and secure with a nut and washers. While
tightening the nut, hold the cable in position so it
is parallel with the starter.

INSTALLING (AWS VI Models)

1. Place the lower mounting bracket into position and

secure with the lock nuts.

! WARNING

When using compressed air to dry components,
always wear safety glasses.

! WARNING

Be sure to keep clear of the pinion gear area as it
will spin at a high RPM when the red cable is
touched to the positive stud. Personal injury may
result if contact is made with a spinning pinion.

! CAUTION

Check the cable installation to make sure it isn’t
near any moving parts or against any sharp
edges.

! CAUTION

Check the cable installation to make sure it isn’t
near any moving parts or against any sharp
edges.

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