ELECTRICAL COMPONENTS: 850 GASOLINE VEHICLE
Starter/Generator
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
Page 14-3
14
Brush Spring Inspection and Replacement
1. Visually inspect springs. Replace all four springs if any spring is discolored from heat (straw or bluish in
color).
2. Install the four brushes (27) into their holders and insert the four brush springs (28)
(Figure 14-3,
Page 14-2)
. Using a spring scale, test brush spring tension. If any spring has a tension less than 24
ounces (6.67 N), replace all four springs
(Figure 14-5, Page 14-3)
.
See following CAUTION.
ý
CAUTION
• When checking brush spring tension, do not push springs beyond the point they would
normally be if there were new brushes installed. Exerting excessive force or pushing brush
springs beyond their normal maximum extension point will damage springs.
Starter/Generator Assembly
1. Connect the brush wires to the holders using four lock washers (26) and four screws (25), making sure
the crossover leads are connected also. Tighten the screws to 31 in-lb (3.5 N·m)
(Figure 14-3,
Page 14-2)
.
2. To prevent contact between the brushes and commutator as the commutator is installed, and possible
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 14-6, Page 14-4)
.
3. Install the commutator end cover (23) onto the armature shaft. Align the locating pin with the pin hole in
the cover. Install two M6 x 180 mm bolts (20) and tighten to 100 in-lb (11.3 N·m)
(Figure 14-2,
Page 14-2)
.
4. Push the brushes down into the holders. Position 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 cov-
ers (29) in the openings in the commutator end cover (23)
(Figure 14-3, Page 14-2)
.
Figure 14-5 Brush Spring Tension Test
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