ELECTRICAL SYSTEMS
8.172004 Four Stroke PWC Service Manual
Starter Assembly
1. Install brush plate to field magnet housing
aligning index tab.
2. Install O-ring, two small phenolic spacers, large
phenolic washer , flat washer, lock washer, and
terminal nut.
3. While holding brush springs away from brushes,
push brushes back and hold in place.
4. Slide armature into field magnet housing.
Release brushes.
5. Lightly grease drive end bushing and reinstall
drive end frame on armature. Inspect seal for
wear or damage. Replace drive end cap if
necessary.
6. Be sure wire insulation is in place around
positive brush wire and pushed completely into
slot on phenolic plate.
7. Using a non-petroleum grease, lubricate brush
end bushing and install shims.
8. Align brush plate and install cover and screws.
9. Reinstall bolts and tighten evenly and securely.
10. Lightly grease pinion shaft and install pinion,
spring stopper, and snap ring.
Starter Solenoid Bench Test
To measure the resistance of the pull-in coil, connect
one meter lead to the Yellow/Red wire and the other
to ground. The resistance should be 2.8-3.6 ohms.
Refer to Electric Starter System Testing in this
section to further test the solenoid.
Nyogelt Grease PN 2871329
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