Club Car 1997 DS, Maintenance Service Supplement

Page: 123 / 164

Page 115
G
12
Assembly of the Starter/Generator
1. Place the field coil inside of the housing. The two insulators that look the same fit into the slots next to
the F1 and F2 markings on the outside of the housing. The insulator that looks different slides into the
slot next to the DF marking. After the insulators are seated in the slots, install the threaded terminals
through the wire connectors and then through the insulators. Install a flat washer and a lockwasher
onto each threaded terminal (on the outside of the housing). Use a nut to secure the washers and insu-
lator to the housing. Tighten nuts to 43-52 in.lbs. (4.8/5.9 N-m) (Figure 12-45, Page 113).
2. Install the four pole pieces into the housing. Use the four screws to secure pole pieces to the inside of
the housing to retain the field wires. Tighten screws to 9 ft.lbs. (12 N-m) (Figure 12-45, Page 113).
3. Slide the bearing retainer onto the output end of the armature shaft (33) so that it will hold the outside
of the bearing (35) only. Press a new ball bearing (35) onto the output end of the armature (Figure 12-
42, Page 111). Press a new ball bearing onto the commutator end of the armature shaft
.
4. Install the output end cover (36) into the armature. Secure the bearing retainer (32) to the cover using
the three M5 x 18mm screws (43). Tighten the screws to 35-43 in.lbs. (3.9/4.8 N-m) (Figure 12-42,
Page 111).
• ROUTE THE FIELD TERMINAL WIRES SO THAT THEY WILL NOT CONTACT THE ARMATURE.
FIGURE 12-47
• TO PREVENT DAMAGE TO THE RETAINER USE CARE WHILE PRESSING NEW BEARING ON
TO THE OUTPUT END OF THE SHAFT.
• PRESS AGAINST THE INNER RACE OF THE NEW BEARING UNTIL IT IS FULLY SEATED.
CAUTION
OFF
DC V
DATA HOLD
AC V
AC/DC 500V MAX
250V MAX
M
METER READS 10.00
("1" FLASHES)
COMMUTATOR
ARMATURE
ARMATURE SHAFT
CAUTION