Ski-Doo Formula S 1998, Shop Manual

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Section 06 ELECTRICAL
Subsection 06 (ELECTRIC STARTER)
06-06-4
CLEANING AND INSPECTION
Refer to the end of this subsection.
ASSEMBLY
Prior to assembling, coat sliding surfaces and
moving parts on armature shaft splines, overrun-
ning clutch, solenoid switch plunger, drive lever
and bushings with G.E. Versilube G 321 (P/N 413
7040 00) lubricant.
Proceed as follows for assembling.
Secure drive housing in a vise.
Install overrunning clutch onto armature shaft. In-
sert
inner collar onto shaft. Install a new circlip.
Insert outer collar being careful to match protru-
sions with notches of collars.
Using a pair of pliers on each side of stop collars,
squeeze evenly until collars sit over circlip.
1. Squeeze evenly
Install thrust washer against outer stop collar.
Place drive lever onto overrunning clutch then in-
sert into drive housing.
1. Install on overrunning clutch
2. Install thrust washer
Slide yoke over armature.
Install brush holder then brushes in their hous-
ings. Insert springs as follows: place one end of
spring against brush, compress, then push the
other end of spring onto its housing. Repeat for
remaining springs.
1. This end first
2. Push this end to complete
Secure insulator over brushes and springs. Prop-
erly install end frame and tighten screws.
Insert solenoid plunger inside of drive lever fork
and secure to drive housing.
Connect starter bare wire to solenoid.
NOTE: Connect this wire on the shorter solenoid
stud.
-
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.
-
CAUTION
Do not overtighten since housing might be
damaged.
-
CAUTION
Always install a new circlip when servicing.
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