Club Car DS Villager 4, Maintenance And Service Manual

Page: 373 / 510

GASOLINE VEHICLE - ELECTRICAL
COMPONENTS Starter/Generator
19
2. To prevent contact between the brushes and commutator as the commutator is installed, and possible damage
to the brushes, lift the brush springs 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 19-5, Page 19-7) .
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 lb·in (11.3 N·m)
(Figure 19-1, Page 19-5) .
4. Push the brushes down into the holders. Position springs on the end of 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 19-2, Page 19-5) .
Figure 19-5 Pull Brushes Away From Center of the Commutator End Cover
DISASSEMBLY OF THE STARTER/GENERATOR TO SERVICE THE
ARMATURE/COMMUTATOR
1. Remove the commutator end cover to prevent damage to the brushes and armature. See Commutator End
Cover on page 19-5.
2. To separate armature and output end cover assembly from the field coil housing, first remove the two securing
bolts (43). Carefully remove armature and output end cover assembly from the field coil housing so components
are not damaged.
3. To separate armature (33) from output end cover (36), remove nut (41), lock washer (40), pulley (39). It may be
necessary to use the wedge attachment tool to remove the pulley from the shaft.
4. Remove the internal retaining ring (32) to release the bearing (35) and armature (33) from the output end cover
(36)
(Figure 19-6, Page 19-8) .
2020 Precedent,Villager 2 and 4 Maintenance and Service Manual Page 19-7