Sea-doo Challenger 5896, Shop Manual

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Section 08 ELECTRICAL
Sub-Section 08 (STARTING SYSTEM)
08-08-5
Check commutator for roughness, burnt or
scored surface. If necessary, turn commutator on
a lathe, enough to resurface only.
Check commutator for mica depth. If depth is less
than 0.20 mm (.008 in), undercut mica. Be sure
that no burrs are left and no copper dust remains
between segments after undercutting operation
is completed.
1. Commutator undercut 0.20 mm (.008 in)
Check commutator out of round condition with V-
shaped blocks and an indicator. If commutator out
of round is more than 0.40 mm (.016 in), commu-
tator should be turned on a lathe.
Check commutator outer diameter. If less than 27
mm (1.063 in), replace.
Brush Holder
Check brush holder for insulation using an ohm-
meter. Place one test probe on insulated brush
holder and the other test probe on brush holder
plate. If continuity is found, brush holder has to be
repaired or replaced.
Brush Length
Measure brush length. If less than 8.5 mm (.335
in), replace them.
NOTE : New brush length is 12 mm (.472
in).
1. New
2. Wear limit, 8.5 mm (.335 in)
Overrunning Clutch
Pinion of overrunning clutch should turn smoothly
in clockwise direction, and should not slip in a
counterclockwise direction. If defective, replace.
Check pinion teeth for wear and damage. If defec-
tive, replace.
NOTE : Always check engine ring gear teeth
for wear and damage. If defective replace
ring gear. Refer to ENGINE 03-04 then refer to
Ring Gear .
ASSEMBLY
Reverse the order of disassembly to reassemble
starter. However, attention should be paid to the
following operations.
Prior to assembling, coat sliding surfaces on ar-
mature shaft splines, overrunning clutch and
bushing with G.E. Versilube G 341 M or ESSO
Beacon 325 lubricant or equivalent.
Apply motor oil on metal bushings.
10,11, Circlip and Pinion Stop Collar
After placing stop collar on armature shaft, fit cir-
clip into armature shaft, then make sure that it is
properly secured.
Slide stop collar over circlip and secure in place by
punching it at 2 or 3 places.
F01H0RA
1
A03E06A
'
A03E05A
2
1
'