Club Car 1997 DS, Maintenance Service Supplement

Page: 124 / 164

Page 116
12
G
Starter/Generator Assembly, Continued:
5. Slide the housing with field coils over the armature. Use the locating pin to align housing to the cover.
6. To prevent contact between brushes and commutator as the commutator cover is installed, and possi-
ble 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 12-41, Page 110).
7. Install the commutator end cover (23) onto the armature shaft. Align the locating pin with the pin hole in
the cover. Install the two M6 x 180mm screws (20) and tighten them to 95-104 in.lbs. (10.6/11.6 N-m)
(Figure 12-37, Page 108).
8. Install the brushes into the holders. Place springs into the notches in the brushes. Install the brush
cover (30) that has the drain hole in it next to the A2 terminal. Install the remaining three brush covers
(29) in the openings in the commutator end cover (23) (Figure 12-39, Page 108).
9. Slide the spacer (37) onto the end of the shaft. Insert the shaft key (34) into the shaft. Install the belt
pulley (39) onto the shaft, then install the the lockwasher (40) and M14 nut (41). Tighten the nut to 25-
30 ft. lbs. (34/41 N-m) of torque (Figure 12-42, Page 111).
Installing the Starter/Generator (Figure 12-48)
1. Install the two 3/8 hex head pivot screws (5) into the mounting bracket with the heads of the screws fac-
ing towards the driver side of the vehicle. Position the starter/generator in the mounting bracket so that
the screws will go through the bracket before going through the starter/generator. Install a lockwasher
(6) (early 1997 vehicles only) and 3/8 nut (7) onto each screw. Tighten the screws and nuts to finger
tight (Figure 12-48).
2. Install the adjustment screw (11) through the adjusting bracket (4) and then through the starter/genera-
tor. Install a lockwasher (9) and 5/16 nut (12) onto the end of the adjustment screw (11). Tighten to fin-
ger tight (Figure 12-48).
3. Install the belt (3) then tighten the mounting screws (See Belt Adjustments on next page).
4. Connect the yellow wire from the voltage regulator to the DF terminal on the starter/generator (Figure
12-2, Page 83). Install a flat washer, lockwasher, and nut onto the terminal. Torque the nut to 26-35
in.lbs. (3.0/4.0 N-m).
5. Install the white wire from the solenoid to the F2 terminal on the starter/generator. Install the black wire
from the frame to the A2 terminal on the starter/generator. Install the green wire from the F1 to the A1
terminal on the starter/generator (Figure 12-2, Page 83). Install a flat washer, lockwasher, and nut onto
each terminal. Torque the nuts to 43-52 in.lbs. (4.8/5.9 N-m).
6. Reinstall the access panel (Figure 12-35, Page 106).
7. Install the seat on the rear body.
• THE TERMINAL INSULATORS SHOULD BE ON THE COMMUTATOR END OF THE HOUSING.
• 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 82).
• FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED.
• SEE THE SAFETY WARNINGS ON PAGE 81.
NOTE
WARNING