ELECTRICAL SYSTEMS
8.16
2004 Four Stroke PWC Service Manual
Starter Motor -- Inspection
Brush Inspection
1. Measure length of each carbon brush. Replace brush
assembly when worn to 5/16″ (8 mm) or less. The
brushes must slide freely in their holders.
Brush Replacement
1. Remove terminal nut with lock washer, flat washer,
large phenolic washer, 2 small phenolic spacers, and
sealing O-ring. Inspect O-ring and replace if damaged.
2. Slide positive brush springs to the side, pull brushes
out of their guides and remove brush plate.
Cleaning
CAUTION:
Some cleaning solvents may damage the insulation in the
starter . Care should be exercised when selecting an ap-
propriate solvent. If the commutator needs cleaning use
only an electrical contact cleaner .
Armature Testing
1. Using a digital multitester , measure resistance
between each of the segments of the commutator. The
reading should indicate .3 ohms or less.
2. Measure resistance between commutator and
armature shaft. Reading should be infinite (OL).
Inspect surface of commutator wear or discoloration.
Replace if excessively worn or damaged.
3. Place armature in a growler . With growler on, position
a hacksaw blade lengthwise, 1/8″ (.3 cm) above
armature coil laminates. Rotate armature 360°.Ifthe
hacksaw blade is drawn toward the armature on any
point, the armature is faulty and must be replaced.
4. Inspect permanent magnets in starter housing. Make
sure they are not cracked or separated from housing.
CAUTION:
Use care when handling starter housing. Do not drop or
strike the housing as magnet damage is possible. If mag-
nets are damaged, starter must be replaced.
Carbon Brush
Service Limit 5/16 (8mm)
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