Servicing 2-cycle starter/generator

Pocono Country Boy · 09-08-2010, 07:30 AM

Anybody have any info or good links to tutorials on how to change brushes and perform other maintenance on these starter/generators?

PS.. It's for an 88/89 PG-2 motor setup

TIA!

Dave Box · 09-08-2010, 07:39 AM

Removal and checking of the brushes is fairly easy. On the opposite end to the pully are four rubber plugs. Remove these and you will see the brushes and brush holders. Loosen the philips head screw and once you have it loose use a long nose pair of pliers to stop it flying out under pressure of the spring when the screw is completely undone.
Replacement of the brushes is a reversal of this proceedure, taking into account that it is neccessary to ensure that the brush seats all the way in the holder and doesn't get hung up.

Dave Box

kogieblack · 09-08-2010, 07:50 AM

That's easily said than done. The best way to change the brushes is to open the end where the brush holder is. Remove the 2 long but thin bolts. Tap out the brush holder. Then you have full and clear access.

Pocono Country Boy · 09-08-2010, 09:42 AM

Thanks Fellas,

It's working fine now but I'm always looking for info to help down the road...especially with older machines.

I was curious though why these starter/generators don't have any case ventilation. I imagine it's to keep out the weather but it seems that it would benefit from some flow-through to cool it down. When I do a 10 mile cruise the doggone thing gets pretty warm.

Dave Box · 09-08-2010, 09:59 AM

It's always a good plan to gather your knowledge before you need it so kudos to you. I would say that if you remove the cables from the generator I found it was neccessary to place a thin wrench under the cable to prevent the post turning. Other than that with the unit on the bench it took about 30 minutes to remove and check the 4 brushes. After that I tested the unit by putting it on axle stands and connecting a DVM to the battery. Under medium speed I got about 14.5 volts and that was close enough for me.
All the best
D Box

Pocono Country Boy · 09-08-2010, 10:28 AM

Thanks Dave,

I did the same kind of check with my cart on jackstands and found about 14.5 also so I'm not worried about it for now... I did the double wrench thing when I swapped out my cables. When I got the cart it had the skinny little #6 cables for everything with pretty shoddy looking ends on them so I replaced the main battery cables with #2's and the others with #4's. IMO bigger is better for the most part when it comes to electrical cable ;)

Thanks for the info!

09-08-2010, 07:30 AM	#1
Pocono Country Boy Gone Wild Join Date: Aug 2010 Location: Pocono Mountains, PA Posts: 162	Servicing 2-cycle starter/generator Anybody have any info or good links to tutorials on how to change brushes and perform other maintenance on these starter/generators? PS.. It's for an 88/89 PG-2 motor setup TIA!

09-08-2010, 07:50 AM	#3
kogieblack Gone Wild Join Date: Apr 2009 Location: Vegas NV Posts: 262	Re: Servicing 2-cycle starter/generator That's easily said than done. The best way to change the brushes is to open the end where the brush holder is. Remove the 2 long but thin bolts. Tap out the brush holder. Then you have full and clear access.

09-08-2010, 09:59 AM	#5
Dave Box Respect the Cart Join Date: May 2010 Location: Rocky Mount, Virginia Posts: 2,190	Re: Servicing 2-cycle starter/generator It's always a good plan to gather your knowledge before you need it so kudos to you. I would say that if you remove the cables from the generator I found it was neccessary to place a thin wrench under the cable to prevent the post turning. Other than that with the unit on the bench it took about 30 minutes to remove and check the 4 brushes. After that I tested the unit by putting it on axle stands and connecting a DVM to the battery. Under medium speed I got about 14.5 volts and that was close enough for me. All the best D Box Last edited by Dave Box; 09-08-2010 at 10:00 AM.. Reason: grammar

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09-08-2010, 07:39 AM	#2
Dave Box Respect the Cart Join Date: May 2010 Location: Rocky Mount, Virginia Posts: 2,190	Re: Servicing 2-cycle starter/generator Removal and checking of the brushes is fairly easy. On the opposite end to the pully are four rubber plugs. Remove these and you will see the brushes and brush holders. Loosen the philips head screw and once you have it loose use a long nose pair of pliers to stop it flying out under pressure of the spring when the screw is completely undone. Replacement of the brushes is a reversal of this proceedure, taking into account that it is neccessary to ensure that the brush seats all the way in the holder and doesn't get hung up. Dave Box

09-08-2010, 09:42 AM	#4
Pocono Country Boy Gone Wild Join Date: Aug 2010 Location: Pocono Mountains, PA Posts: 162	Re: Servicing 2-cycle starter/generator Thanks Fellas, It's working fine now but I'm always looking for info to help down the road...especially with older machines. I was curious though why these starter/generators don't have any case ventilation. I imagine it's to keep out the weather but it seems that it would benefit from some flow-through to cool it down. When I do a 10 mile cruise the doggone thing gets pretty warm.

09-08-2010, 10:28 AM	#6
Pocono Country Boy Gone Wild Join Date: Aug 2010 Location: Pocono Mountains, PA Posts: 162	Re: Servicing 2-cycle starter/generator Thanks Dave, I did the same kind of check with my cart on jackstands and found about 14.5 also so I'm not worried about it for now... I did the double wrench thing when I swapped out my cables. When I got the cart it had the skinny little #6 cables for everything with pretty shoddy looking ends on them so I replaced the main battery cables with #2's and the others with #4's. IMO bigger is better for the most part when it comes to electrical cable ;) Thanks for the info!