Yamaha's Raptor 660 sport ATVs end an electric starter Engine to bring their engines to activity. The starter Engine itself is petite and than an electromagnet, which relies on a spinning, shaft-like armature attached to a round Hand-bill commutator. A fix of carbon brushes provides an electrical charge when the starter Press-stud is pressed, turning the commutator on ice attraction. A gear attached to the confine of the armature then turns the engine's starter clutch until internal combustion can accommodate sufficient potency to function the engine. A damaged starter Engine can be rebuilt, nevertheless alone after performing a battery of tests.
Instructions
Starter Motor Removal
1. Grounds the ATV on a continuous attempt environment and establish the parking brake. Pull the inner cap and O-ring, located near the starter Engine shaft, off the starter motor housing. Pull the series of washers off the end of the starter armature coil, the long, shaft-like structure at the center of the housing. In total, there will be a washer with four upturned tabs and three flat washers.6.
Unscrew the mounting bolts along the top of the muffler, using a 12 mm socket. Pull the muffler off the exhaust main. Remove the exhaust channel nuts, located on the hold water side of the engine cylinder, using a 12 mm socket. Measure the diameter of the commutator, the wider outside portion of the armature coil, using a micrometer. The commutator should have a minimum diameter of 1.06 inches. Replace the armature coil if the commutator diameter is less than 1.06-inches.
Unscrew the terminal fan from the top of the starter Engine, using a 10 mm socket. Lift the electrical example off of the terminal publish. Pull the starter Engine and O-ring to the condign and outside from the engine.
Starter Motor Inspection and Assembly
4. Remove the guide gear circlip from the head of the starter Engine output shaft, using outside snap call pliers. Pull the impel gear off the starter Engine.
5. Remove the couple of bolts from the outer aim cap of the starter Engine housing, using a 10 mm socket. Remove the seat, using the Proceeds lever at the rear of the seat cushion. Disconnect the contradiction cable from the battery's dissension terminal, indicated by a minus symbol, using a Phillips screwdriver.2. Loosen the clamp attaching the muffler to the exhaust channel, using a 12 mm socket and a socket wrench.
Pull the outer end cap off the starter motor housing. Slip all three shims off the end of the starter armature coil. Pull the brush plate out from the housing, then pull out the armature coil. Push the starter motor terminal post into the starter housing, then pull out the terminal and the attached brushes. Pull the armature coil yoke from the outer side of the starter housing.
7. Pull the exhaust channel out from the engine.3. Remove the parking cable holder from the honorable side of the starter Engine, using a 10 mm socket.
8. Measure the undercut, or depth, of the grooves cut along the length of the armature coil, between the commutator and the output shaft. The grooves should be 0.03-inch deep. Cut into any grooves that are less than 0.03-inch deep, using a hacksaw blade.
9. Set a multimeter to the RX10 resistance range, indicated by an omega symbol, using the meter's selector knob. Touch both of the meter's probes to the commutator. The meter should give a resistance reading between 0.025 to 0.035 ohms. Move the meter's black probe to one of the grooves cut into length of the armature coil. The meter should provide a resistance reading of 106 ohms. Replace the armature coil if either resistance reading was not within its specified range.
10. Measure the thickness of the brush pads at both ends of the brush assembly. The brushes must have a minimum thickness of 0.20-inch. Replace the brush assembly, if either brush is thinner than 0.20-inch.
11. Push the armature coil yoke into the outer end of the starter motor housing. Place the brush assembly into the starter motor housing, followed by the threaded terminal post. Push the brush plate into the outer end of the starter housing, followed by the armature coil.
12. Slide all three shims onto the protrusion at the tip of commutator, then push the outer end cap and a new O-ring onto the starter motor housing. Place three flat washer over the armature coil output shaft, followed by the tabbed washer, facing its upturned tabs toward the tip of the output shaft. Push the inner end cap and a new O-ring over the output shaft tip, followed by the drive gear. Place a new circlip into the channel cut into the tip of the output shaft.
13. Push the starter motor bolts into the outer end cap, through the stater motor housing, to the inner end cap. Tighten the bolts to 3.6 foot-pounds, using a torque wrench.
Starter Motor Installation.
14. Hold the starter motor to the right of the engine. Push the starter motor drive gear into the engine crankcase.
15. Place the parking brake cable holder against the L-shaped tabs cast into the outer starter motor end cap, then screw the holder mounting bolts into place. Tighten both bolts to 7.2 foot-pounds. Place the starter motor lead onto the starter motor terminal post, then tighten the terminal nut into place.
16. Mount the exhaust pipe onto the engine. Loosely tighten the exhaust pipe nuts. Push the muffler onto the exhaust pipe, then loosely screw the muffler mounting bolts into place. Reposition the exhaust pipe and muffler until everything is aligned, then tighten the muffler bolts to 19 foot-pounds. Tighten the muffler clamp to 14 foot-pounds, Tighten the exhaust pipe nuts to 7.2 foot-pounds.
17.Connect the negative cable to the battery's negative terminal, then tighten the terminal bolt. Reinstall the seat onto the ATV.
