Ski-Doo Formula 500 1998, Shop Manual

Page: 242 / 398

Section 06 ELECTRICAL
Subsection 05 (ELECTRIC STARTER)
06-05-2
REMOVAL
– Disconnect BLACK ground cable from battery.
– Disconnect RED positive cable from battery.
– Disconnect RED cable and RED/GREEN wire
from starter solenoid switch.
– Remove starter from engine.
DISASSEMBLY
Disconnect bare wire linking starter and solenoid.
Remove nuts no. 16 then solenoid switch no. 10
by lifting and pulling to disengage from drive lever
no. 15 .
Unscrew starter screws (long) no. 1 then pull
yoke no. 8 with end frame no. 2 to separate from
drive housing no. 17 .
Pull armature no. 9 with drive lever no. 15 .
Remove insulator no. 4 then brush springs no. 7
being careful not to lose them since they will be
projected out.
Pull brush holder no. 5 from yoke no. 8 .
Insert blade of a small screwdriver between stop
collars.
Twist screwdriver to separate stop collars no. 12
thus giving access to circlip no. 13 .
Remove outer collar, circlip then inner collar.
Remove overrunning clutch no. 11 .
Check the wear on bushing no. 18 by measuring
the amount of radial play between the armature
shaft and the bushing.
The radial play should not exceed 0.20 mm (.008 in).
If greater, replace the bushing. To replace, press
out the old one toward bushing cover and press in
a new one with a bushing pusher. The correct size
of the bushing pusher to use is given on next illus-
tration.
BUSHING PUSHER
A. 16 mm (5/8 in) dia.
B. 13 mm (1/2 in)
C. 11 mm (7/16 in)
D. 11.0 mm (.433 in)
1. Press-in
2. Bushing pusher
3. Bushing
4. Drive housing
◆
WARNING
Always disconnect ground cable first and
connect last.
A19E01A
-
CAUTION
Support drive housing adequately to pre-
vent damage when pressing bushing.
A19E0AA
B
C
D
A
D
A19E0BA
1
2
3
4