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Yamaha XV920 Virago Manual

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8A-14
Chapter 8 Part A Electrical system (XV535 models)
25.2 Four-brush starter motor - exploded view
1 Through-bolt 6 Cable
2 Lockwasher 7 O-rings
3 Brush end cover 8 Starter housing
4 Brush plate 9 O-ring
5 Plastic brush housing 10 Armature
25.5 Two-brush starter - exploded view
1 Cable 7 Washer
2 Terminal nuts and washers 8 O-ring
3 Brush end cover _, 9 Through-bolt
4 Brush plate 10 Armature
5 O-ring 11 Starter housing
6 Mounting bolt
Disassembly
Four-brush starter
Refer to illustration 25.2
2 Mark the position of the housing to each end cover. Remove the
two through-bolts and their lockwashers and detach both end covers
(see illustration).
3 Remove the nut and push the terminal bolt through the starter
housing, then reinstall the washers and nut on the bolt so you don't
forget how they go. Pull the armature out of the housing and remove
the brush plate.
4 Remove the two brashes with the plastic holder from the housing.
Two-brush starter
Refer to illustration 25.5
5 Mark the position of the housing to each end cover. Remove the
two through-bolts and detach both end covers (see illustration).
6 Remove the shims and brush plate from the brush housing after
the terminal bolt nut and washers have been removed - note he exact
order of the washers.
7 Pull the armature out of the housing (toward the pinion gear side).
Inspection
Refer to illustrations 25.8, 25.9, 25.10a, 25.10b, 25.11, 25.12 and
25.18
8 The parts of the starter motor that most likely will require attention
are the brushes. Measure the length of the brushes and compare the
results to the brush length listed in this Chapter's Specifications (see
illustration). If any of the brushes are worn beyond the specified limits,
replace the brush holder assembly with a new one. If the brushes are
not worn excessively, cracked, chipped, or otherwise damaged, they
may be re-used.
9 Inspect the commutator (see illustration) for scoring, scratches
25.8 Measure the length of the brushes and compare the length
of the shortest brush with the length listed in this Chapter's
Specifications (four-brush starter shown; twp-brush
model similar)
and discoloration. The commutator can be cleaned and polished with
crocus cloth, but do not use sandpaper or emery paper. After cleaning
wipe away any residue with a cloth soaked in an electrical system
cleaner or denatured alcohol. Measure the commutator diameter and
compare it to the diameter listed in this Chapter's Specifications. If it is
less than the service limit, the motor must be replaced with a new one
10 Using an ohmmeter or a continuity test light, check for continuity
between the commutator bars (see illustration). Continuity should
exist between each bar and all of the others. Also, check for con-
tinuity between the commutator bars and the armature shaft
(see illustration). There should be no continuity between the
commutator and the shaft. If the checks indicate otherwise, the
… 317 …


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