Ski-Doo Formula 500 1998, Shop Manual

Page: 243 / 398

Section 06 ELECTRICAL
Subsection 05 (ELECTRIC STARTER)
06-05-3
Install bushing cover no. 19 then, using a punch,
stake bushing cover in place.
1. Stake bushing cover
2. Support
3, Bushing (end frame)
Check the wear on bushing no. 3 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 bushing as follows:
Using a 12 mm tap, cut threads into bushing so
that the tap contacts the end frame. Continue to
rotate tap until the bushing comes free.
1. Turn until bushing goes out
2. 12 mm tap
To install new bushing, use the same bushing
pusher as for drive housing bushing installation.
6, Brush
To replace brush no. 6 , proceed as follows:
Cut brush wire close to connector at the welded
portion.
1. Cut close to connector
Remove burrs with a file on the remaining welded
portion.
Place spare brush plate edge against yoke con-
nector edge (welded portion).
Crimp plate over yoke connector with a pair of pliers.
1. Plate edge
2. Yoke connector
3. Crimp
4. Spare brush
Solder the crimped portion.
A19E02A
1
2
A19E03A
1
2
-
CAUTION
Be careful not to damage plastic portion of
yoke.
-
CAUTION
Do not overheat and quickly perform solder-
ing to prevent solder from flowing to the
brush through the wire. Preferably use a
heat sink.
A19E05A
1
A19E06A
1
2
3
4