ELECTRICAL 2 B BATTERY CHARGING SYSTEM AND STARTING SYSTEM

ELECTRICAL 2 B BATTERY CHARGING SYSTEM AND STARTING SYSTEM 51797

Tle of Contents Pge Speifitions................................ 2B-1 Speil Tools................................ 2B-1 Bttery...................................... 2B-2 Preutions............................... 2B-2 Speifi Grvity Redings..................... 2B-2 Speifi Grvity Cell Comprison Test........ 2B-3 Eletrolyte Level............................. 2B-3 Chrging Dishrged Bttery................. 2B-3 Winter Storge of Btteries.................... 2B-4 Bttery Chrging System Desription........... 2B-4 Bttery Chrging System Trouleshooting....... 2B-5 Generl Trouleshooting................... 2B-5 40 Ampere Alterntor System............... 2B-5 40 Amp Sttor Test (Alterntor Coils Only). 2B-5 Trouleshooting 40 Amp Alterntor System... 2B-5 Determining Cuse of Prolem........... 2B-6 Prolem: Constnt High Output.......... 2B-6 Prolem: No Output..................... 2B-6 Regultion Voltge Chek............... 2B-6 Voltge Regultor Test (Using Ohm Meter) 2B-7 Removl of Voltge Regultors........... 2B-7 Instlltion of Voltge Regultor/Retifier.. 2B-7 Pge Inorporting Bttery Isoltor With V-6 40 Amp Chrging System............... 2B-8 System Wired for Split Output............... 2B-8 20 Amperes to Auxiliry Bttery; 20 Amperes to Crnking Bttery.......... 2B-8 System Wired for 40 Ampere Output to Isoltor................................ 2B-9 Strter System........................... 2B-10 Strter System Components............ 2B-10 Desription........................... 2B-10 Trouleshooting the Strter Ciruit....... 2B-10 Strter Ciruit Trouleshooting Flow Chrt... 2B-11 Strter Removl nd Instlltion............ 2B-12 Removl............................. 2B-12 Instlltion............................ 2B-13 Disssemly.......................... 2B-13 Strter Clening, Inspetion nd Testing..... 2B-14 Clening nd Inspetion................ 2B-14 Testing............................... 2B-14 Strter Ressemly.................... 2B-16 Strter Solenoid Test................... 2B-18 2B-0 - ELECTRICAL 90-824052R2 SEPTEMBER 1997

Speifitions Strter Drw (No Lod) Strter Drw (Under Lod) Bttery Rting Alterntor Output (@ eh regultor 19-21 mperes) Voltge Regultor Drw with Ignition Key in the OFF Position 40 Amperes 175 Amperes 630 Mrine Crnking Amperes (MCA) 490 Cold Crnking Amperes (CCA) 38-42 Amperes Net @ 5000 RPM 2 10 Millimperes EACH*. Totl system drw: 4 20 Millimperes. Speil Tools Multi-Meter DVA Tester 91-99750 NOTE: Due to the ft tht the voltge regultors drw voltge when the ignition key is in the OFF position, notile sprk will our when the ttery les re tthed to the ot ttery. Hydrometer (otin lolly) Ammeter (otin lolly) 90-824052R2 SEPTEMBER 1997 ELECTRICAL - 2B-1

Bttery Preutions WARNING If ttery id omes in ontt with skin or eyes, wsh skin immeditely with mild sop. Flush eyes with wter immeditely nd see dotor. When hrging tteries, n explosive gs mixture forms in eh ell. Prt of this gs espes through holes in vent plugs nd my form n explosive tmosphere round ttery if ventiltion is poor. This explosive gs my remin in or round ttery for severl hours fter it hs een hrged. Sprks or flmes n ignite this gs nd use n internl explosion whih my shtter the ttery. The following preutions should e oserved to prevent n explosion. 1. DO NOT smoke ner tteries eing hrged or whih hve een hrged very reently. 2. DO NOT rek live iruits t terminls of tteries euse sprk usully ours t the point where live iruit is roken. Alwys e reful when onneting or disonneting le lmps on hrgers. Poor onnetions re ommon use of eletril rs whih use explosions. 3. DO NOT reverse polrity of ttery terminl to le onnetions. Speifi Grvity Redings Use hydrometer to mesure speifi grvity of eletrolyte in eh ell. Hydrometer mesures perentge of sulfuri id in ttery eletrolyte in terms of speifi grvity. As ttery drops from hrged to dishrged ondition, id leves the solution nd enters the pltes, using derese in speifi grvity of eletrolyte. An indition of onentrtion of eletrolyte is otined with hydrometer. When using hydrometer, oserve the following points: 1. Hydrometer must e len (inside nd out) to insure n urte reding. 2. Never tke hydrometer redings immeditely fter wter hs een dded. Wter must e thoroughly mixed with eletrolyte y hrging for t lest 15 minutes t rte high enough to use vigorous gssing. 3. If hydrometer hs uilt-in thermometer, drw liquid in severl times to ensure orret temperture efore tking reding. 4. Hold hydrometer vertilly nd drw in just enough liquid from ttery ell so tht flot is freefloting. Hold hydrometer t eye level so tht flot is vertil nd free of outer tue, then tke reding t surfe of liquid. Disregrd urvture where liquid rises ginst flot stem due to pillrity. 22532 5. Avoid dropping eletrolyte on ot or lothing, s it is extremely orrosive. Wsh off immeditely with king sod solution. Speifi grvity of eletrolyte vries not only with perentge of id in liquid ut lso with temperture. As temperture inreses, eletrolyte expnds, so tht speifi grvity is redued. As temperture drops, eletrolyte ontrts, so tht speifi grvity inreses. Unless these vritions in speifi grvity re tken into ount, speifi grvity otined y hydrometer my not give true indition of id in eletrolyte. 2B-2 - ELECTRICAL 90-824052R2 SEPTEMBER 1997

A fully hrged ttery will hve speifi grvity reding of pproximtely 1.270 t n eletrolyte temperture of 80 F (27 C). If eletrolyte temperture is ove or elow 80 F, dditions or sutrtions must e mde in order to otin hydrometer reding orreted to 80 F stndrd. For every 10 F (3.3 C) ove 80 F, dd 4 speifi grvity points (.004) to hydrometer reding. Exmple: A hydrometer reding of 1.260 t 110 F (43 C) would e 1.272 orreted to 80 F, inditing fully hrged ttery. For every 10 elow 80 F, sutrt 4 points (.004) from the reding. Exmple: A hydrometer reding of 1.272 t 0 F (-18 C) would e 1.240 orreted to 80 F, inditing prtilly hrged ttery. Speifi Grvity Cell Comprison Test This test my e used when n instrumentl tester is not ville. To perform this test, mesure speifi grvity of eh ell, regrdless of stte of hrge, nd interpret results s follows: If speifi grvity redings show differene etween highest nd lowest ell of.050 (50 points) or more, ttery is defetive nd should e repled. Eletrolyte Level Chek eletrolyte level in ttery regulrly. A ttery in use in hot wether should e heked more frequently euse of more rpid loss of wter. If eletrolyte level is found to e low, then distilled wter should e dded to eh ell until liquid level rises pprox. 3/16 in. (4.8mm) over plte. DO NOT OVER- FILL, euse this will use loss of eletrolyte nd result in poor performne, short life nd exessive orrosion. Chrging Dishrged Bttery The following si rules pply to ny ttery hrging sitution: 1. Any ttery my e hrged t ny rte (in mperes) or s long s spewing of eletrolyte (from violent gssing) does not our nd for s long s eletrolyte temperture does not exeed 125 F (52 C). If spewing of eletrolyte ours, or if eletrolyte temperture exeeds 125 F, hrging rte (in mperes) must e redued or temporrily hlted to void dmge to the ttery. 2. Bttery is fully hrged when, over 2-hour period t low hrging rte (in mperes), ll ells re gssing freely (not spewing liquid eletrolyte), nd no hnge in speifi grvity ours. Full hrge speifi grvity is 1.260-1.275, orreted for eletrolyte temperture with eletrolyte level t 3/16 in. (4.8mm) over plte, unless eletrolyte loss hs ourred (from ge or over-filling) in whih se speifi grvity reding will e lower. For most stisftory hrging, lower hrging rtes in mperes re reommended. 3. If, fter prolonged hrging, speifi grvity of t lest 1.230 on ll ells nnot e rehed, ttery is not in optimum ondition nd will not provide optimum performne; however, it my ontinue to provide dditionl servie, if it hs performed stisftorily in the pst. 4. To hek ttery voltge while rnking engine with eletri strting motor, ple RED (+) led of tester on POSITIVE (+) ttery terminl nd BLACK (-) led of tester on NEGATIVE (-) ttery terminl. If the voltge drops elow 9-1/2 volts while rnking, the ttery is wek nd should e rehrged or repled. CAUTION During servie, only distilled wter should e dded to the ttery, not eletrolyte. Liquid level in ells should never e llowed to drop elow top of pltes, s portion of pltes exposed to ir my e permnently dmged with resulting loss in performne. 90-824052R2 SEPTEMBER 1997 ELECTRICAL - 2B-3

Winter Storge of Btteries Bttery ompnies re not responsile for ttery dmge either in winter storge or in deler stok if the following instrutions re not oserved: 1. Remove ttery from its instlltion s soon s possile nd remove ll grese, sulfte nd dirt from top surfe y running wter over top of ttery. Be sure, however, tht vent ps re tight eforehnd, nd low off ll exess wter thoroughly with ompressed ir. Chek wter level, mking sure tht pltes re overed. 2. When dding distilled wter to ttery, e extremely reful not to fill more thn 3/16 in. (4.8mm) ove perforted ffles inside ttery. Bttery solution or eletrolyte expnds from het used y hrging. Overfilling ttery will use eletrolyte to overflow (if filled eyond 3/16 in. ove ffles). 3. Grese terminl olts well with 2-4-C Mrine Lurint nd store ttery in COOL-DRY ple. Remove ttery from storge every 30-45 dys, hek wter level nd put on hrge for 5 or 6 hours t 6 mperes. DO NOT FAST CHARGE. 4. If speifi grvity drops elow 1.240, hek ttery for reson nd rehrge. When grvity rehes 1.260, disontinue hrging. To hek speifi grvity, use hydrometer, whih n e purhsed lolly. 5. Repet preeding hrging proedure every 30-45 dys, s long s ttery is in storge, for est possile mintenne during intive periods to ensure good serviele ttery in spring. When redy to ple ttery k in servie, remove exess grese from terminls ( smll mount is desirle on terminls t ll times), rehrge gin s neessry nd reinstll ttery. WARNING Hydrogen nd oxygen gses re produed during norml ttery opertion or hrging. Sprks or flme n use this mixture to ignite nd explode, if they re rought ner the vent openings. Sulfuri id in ttery n use serious urns, if spilled on skin or in eyes. Flush or wsh wy immeditely with ler wter. Bttery Chrging System Desription The ttery hrging system omponents re the flywheel permnent mgnets, sttor, voltge regultor/ retifier nd ttery. The rotting permnent mgnets indue n lternting urrent (AC) in the sttor oils. The AC urrent is retified to diret urrent (DC) y the voltge regultor/retifier. The DC output from the voltge regultor/retifier is used to hrge the ttery. The voltge regultor/retifier lso senses the ttery voltge s mesure of the ttery s stte of hrge nd therey regultes the DC urrent flow to the ttery. In this mnner, the ttery hrge is mintined nd the ttery is proteted from n overhrge ondition. - 40 Ampere Sttor - Strter Solenoid - To Thometer d - Voltge Regultor e - 12 Volt Bttery d d e 51806 2B-4 - ELECTRICAL 90-824052R2 SEPTEMBER 1997

Bttery Chrging System Trouleshooting Generl Trouleshooting A fult in the ttery hrging system will usully use the ttery to eome UNDERCHARGED. A defetive VOLTAGE REGULATOR my lso llow the system to OVERCHARGE the ttery. If prolem exists in the hrging system, visully hek the following: 1. Chek for orret ttery polrity [RED le to (+) POSITIVE ttery terminl]. NOTE: 40 AMP CHARGING SYSTEM voltge regultor/retifier is proteted internlly ginst inorretly instlled ttery les. 2. Chek for loose or orroded ttery terminls. 3. Chek ondition of the ttery. 4. Visully inspet ll wiring etween sttor nd ttery for uts, hfing nd disonneted, loose or orroded onnetions. 5. Exessive eletril lod (from too mny essories) will use ttery to run down, even if the system is operting orretly. If the system is still OVERCHARGING the ttery, the VOLTAGE REGULATOR is most likely defetive nd should e repled. If the ttery is UNDERCHARGED, proeed with REGULATOR, STATOR, nd RECTIFIER tests, following. 40 Ampere Alterntor System 40 AMP STATOR TEST (ALTERNATOR COILS ONLY) NOTE: Sttor n e tested without removing from engine. 1. Disonnet 2 short YELLOW nd 2 long YEL- LOW sttor leds from ullet onnetors t rer of engine ove ignition oil plte. 2. Use n ohmmeter nd perform the following test: Test Leds To- Connet test leds etween 2 short YELLOW nd 2 long YELLOW sttor leds RED test led to 1 short YELLOW (or long YELLOW) sttor led, nd BLACK test led to engine ground if sttor is mounted or to steel frme of sttor (if off engine) Resistne (Ohms) Sle Reding.25-.45* R x 1 No Continuity R x 1000 * Resistne of these windings generlly is less thn one ohm. A reding, tht resemles short, is eptle. Copper wire is n exellent ondutor ut will hve notiele differenes from old to hot. Resonle vrition from speified reding is eptle. 3. If meter redings re other thn speified, reple sttor ssemly Refer to sttor ssemly replement in Setion 2A. TROUBLESHOOTING 40 AMP ALTERNATOR SYSTEM WARNING Before onneting or disonneting ny eletril onnetion, ttery les MUST BE RE- MOVED from ttery to prevent possile personl injury or dmge to equipment. IMPORTANT: The hrging system my e onneted to one or more tteries during these tests. However, these tteries MUST BE fully hrged. These tteries MUST NOT BE onneted to ny other hrging soure. 90-824052R2 SEPTEMBER 1997 ELECTRICAL - 2B-5

IMPORTANT: Chek tht ll onnetions re tight prior to strting tests. Ensure tht the ttery posts nd terminls re len nd mking good ontt. Verify with test equipment tht wiring hrnesses re not t fult. DETERMINING CAUSE OF PROBLEM 1. Connet outord ttery leds to ttery(s) tht re known to e in good ondition nd re fully hrged. 2. Chek voltge t ttery(s) with n nlog voltmeter. Digitl voltmeters re not reommended s they my e inurte due to interferene from outord ignition system. 3. Strt outord nd run t 1000 RPM. Voltge t ttery should rise to nd stilize t pproximtely 14.5 volts if system is operting properly. If voltge does not inrese from previously heked ttery voltge vlues, refer to NO OUTPUT, following, for trouleshooting proedures. If voltge exeeds 16 volts nd DOES NOT return down to nd stilize t 14.5 volts, refer to CONSTANT HIGH OUTPUT, following for trouleshooting proedures. PROBLEM: CONSTANT HIGH OUTPUT 1. Remove flywheel nd visully inspet sttor. Disolortion of one or more poles, or urned windings will require replement of sttor. 2. If no visul defets of sttor re found, reinstll fly- wheel. Temporrily instll mmeter (of suffiient size to rry 50 mperes) in series with the RED output led (MALE ullet led) of the regultor nd the strter solenoid. 3. Remove 1 short nd 2 long YELLOW sttor leds from their ullet onnetors. Run engine t 1000-2000 RPM. If no output urrent is oserved, disonnet 2 short YELLOW leds nd 1 long YELLOW led. Repet the test with the seond long YELLOW led onneted. Any output urrent indites sttor is shorted to ground. Reple sttor. 4. If there is no output with either short or long YEL- LOW leds disonneted, the regultors re defetive. PROBLEM: NO OUTPUT IMPORTANT: Regultors MUST hve good ground. Verify len ontt surfe exists etween regultor se, powerhed nd tthing hrdwre. 1. Chek voltge on either RED wire to regultor(s) (ullet onnetors). These leds must indite ttery voltge. If ttery voltge is NOT present, wiring etween the test point nd ttery terminls is defetive. Refer to WIRING DIAGRAMS, SECTION 2D. 2. Connet n AC voltmeter to either the 2 short or 2 long YELLOW led ullet onnetors on the regultors. If the AC voltge t idle or ove is greter thn 16 VAC, the regultor is defetive. NOTE: The thometer signl is provided y either regultor. It is possile to still hve n urte thometer signl with defetive regultor. REGULATION VOLTAGE CHECK NOTE: Bttery must e fully hrged efore testing regultion voltge. A low ttery will not llow n urte reding of regultion voltge. 1. Turn on ll eletril essories nd rnk engine for 20 seonds with the ignition lnyrd swith turned off. This will dishrge ttery slightly. 2. Strt engine nd oserve ttery voltge. Voltge should slowly rise to pproximtely 14 to 15 volts. If voltge does not rise, repet previous tests for sttor nd regultor. NOTE: If digitl voltmeter is used for this reding, mesure voltge t the ttery nd keep meter s fr wy from engine s possile. This will redue the possiility of erroneous redings from ignition noise. 2B-6 - ELECTRICAL 90-824052R2 SEPTEMBER 1997

VOLTAGE REGULATOR TEST (USING OHM METER) IMPORTANT: Mke sure meter is zeroed y shorting meter leds together fter hnging seletor kno to pproprite setting. The meter reding must red 0 Ohms. IMPORTANT: The following regultor tests should e performed s soon s possile fter suspeted regultor filure. A old regultor my test GOOD when in ft it is defetive when wrm. Disonnet ll voltge regultor wires. Using Ohm meter, perform eh Ohms test listed elow: REMOVAL OF VOLTAGE REGULATORS 1. Remove 4 loknuts nd spers from oil mounting plte. Ly oil mounting plte off to one side. Prodution Models Test Leds To- Diode Chek: Connet NEGATIVE ( ) ohm led to either YELLOW led. Connet POSITIVE (+) test led to thik RED led. Diode Chek: Connet NEGATIVE ( ) ohm led to thik RED led. Connet POSITIVE (+) ohm led to either YEL- LOW led. SCR Cheks: Connet NEGATIVE ( ) ohm led to either YELLOW led. Connet POSITIVE (+) ohm led to se ground. Thometer Ciruit Chek: Connet NEGATIVE ( ) ohm led to se ground. Connet POSITIVE (+) ohm led to GRAY led. Resistne (Ohms) Sle 100-400 R x 10 40K to 10K to 10K to 30K R x 1K R x 1K R x 1K - 4 Loknuts - 4 Spers (HIDDEN) Pro Mx/Super Mgnum Models 51797 - Regultors - Srews 2. Disonnet 2 YELLOW leds, 2 RED leds nd GRAY th led (if onneted) from respetive ullet onnetors. 3. Remove voltge regultor/retifier from powerhed. INSTALLATION OF VOLTAGE REGULATOR/RECTIFIER 1. Position regultors over tthing studs (prodution models). 2. Connet YELLOW, RED nd GRAY (s required) leds to their respetive ullet onnetors. 3. Position spers over tthing studs (prodution models). 90-824052R2 SEPTEMBER 1997 ELECTRICAL - 2B-7

NOTE: Pro Mx/Super Mgnum regultors re seured to powerhed with olts nd lok nuts. 4. Position oil/solenoid plte over tthing studs. Ple trim ground led (BLACK) onto ottom stud. 5. Seure plte, regultors nd trim ground led to powerhed with loknuts. Torque nuts to 80 l. in. (9.0 N m). INCORPORATING A BATTERY ISOLATOR WITH V-6 40 AMP CHARGING SYSTEM A ttery isoltor will llow the hrging system to hrge oth the strting ttery nd n uxiliry ttery t the sme time while preventing essories, onneted to the uxiliry ttery, from drwing power from the rnking ttery. 1. Instll the isoltor s presried y the mnufturer. IMPORTANT: After eletril onnetions re mde, ot ll terminl onnetions using Quiksilver Liquid Neoprene (92-25711) to void orrosion. 2. Using BATTERY ISOLATOR HARNESS KIT 84-815366A3, hrging system n e wired to provide either 20 mps to uxiliry ttery nd 20 mps to rnking ttery or 40 mps to isoltor. System Wired for Split Output 20 AMPERES TO AUXILIARY BATTERY; 20 AMPERES TO CRANKING BATTERY d e f g h - Strter Solenoid - RED Leds Engine Hrness from Upper Regultor to Strt Solenoid - Disonnet (nd disrd) Engine Hrness RED Leds to Lower Regultor d - Upper Regultor e - Lower Regultor f - Jumper Wire (from kit) g - RED Pigtil Cle (from kit) to Auxiliry Bttery + Terminl h - BLACK Cle (from kit) Route from Auxiliry Bttery Terminl to suitle Engine Ground 2B-8 - ELECTRICAL 90-824052R2 SEPTEMBER 1997

System Wired for 40 Ampere Output to Isoltor IMPORTANT: After eletril onnetions re mde, ot ll terminl onnetions using Quiksilver Liquid Neoprene (92-25711) to void orrosion. k j h d i h e f g - Strter Solenoid - RED Led to Strter Solenoid - Bttery Isoltor d - Strt Bttery e - Auxiliry Bttery f - RED pigtil Cle (from kit) to Bttery Isoltor g - BLACK Cle (from kit) route from Auxiliry Bttery Terminl to Engine Ground h - Plug (from kit) i - Lower Regultor j - Upper Regultor k - RED Leds Engine Hrness from Regultors to Strter Solenoid 90-824052R2 SEPTEMBER 1997 ELECTRICAL - 2B-9

Strter System STARTER SYSTEM COMPONENTS 1. Bttery 2. Strter Solenoid 3. Neutrl Strt Swith 4. Strter Motor 5. Ignition Swith DESCRIPTION The funtion of the strting system is to rnk the engine. The ttery supplies eletriity to tivte the strter motor. When the ignition swith is turned to the START position, the strter solenoid is energized nd ompletes the strter iruit etween the ttery nd strter. The neutrl strt swith opens the strter iruit when the shift ontrol lever is not in neutrl thus preventing identl strting when the engine is in ger. CAUTION The strter motor my e dmged if operted ontinuously. DO NOT operte ontinuously for more thn 30 seonds. Allow 2 minute ooling period etween strting ttempts. TROUBLESHOOTING THE STARTER CIRCUIT Before eginning the trouleshooting flow hrt, verify the following onditions: 1. Confirm tht ttery is fully hrged. 2. Chek tht ontrol lever is in NEUTRAL position. 3. Chek terminls for orrosion nd loose onnetions. 4. Chek les nd wiring for fryed nd worn insultion. 5. Chek 20 mp fuse. Lotion of Test Points (lled out in flow hrt) re numered elow. g 6 2 1 3 f e 3 6 1 2 5 4 d - Strter Solenoid (89-68258) - Strter - Neutrl Strt Swith d - Ignition Swith e - 20 Ampere Fuse f - Strter Solenoid (89-96054) g - Bttery 2B-10 - ELECTRICAL 90-824052R2 SEPTEMBER 1997

Strter Ciruit Trouleshooting Flow Chrt Strter Motor Does Not Turn SAFETY WARNING: Disonnet YELLOW (strter motor) le from strter solenoid test point 1 BEFORE mking tests 1-thru-7 to prevent unexpeted engine rnking. TEST 1 Use n ohmmeter (Rx1 sle) nd onnet meter leds etween NEGATIVE (-) ttery post nd ommon powerhed ground. No Continuity Indited - There is n open iruit in the BLACK NEGATIVE (-) ttery le etween the NEGATIVE (-) ttery post nd the powerhed. Chek le for loose or orroded onnetions. Chek le for open. Continuity Indited Proeed to TEST 2 No voltge reding: proeed to TEST 3. Test 2. Disonnet BLACK ground wire(s) from Test Point 2.. Connet voltmeter etween ommon engine ground nd Test Point 2.. Turn ignition key to Strt position. TEST 3. Reonnet BLACK ground wire.. Connet voltmeter etween ommon engine ground nd Test Point 3.. Turn ignition key to Strt position. 12 Volt Reding* Chek BLACK ground wire for poor onnetion or open iruit. Reonnet ground wire to strter solenoid. Proeed to TEST 7. No voltge reding: Proeed to TEST 4 12 Volt Reding Defetive strter solenoid No voltge reding: Proeed to TEST 5 TEST 4. Connet voltmeter etween ommon engine ground nd Test Point 4.. Turn ignition key to Strt position. 12 Volt Reding* Neutrl strt swith is open or YELLOW/RED wire is open etween Test Points 4 nd 3. No voltge reding: Proeed to Test 6. TEST 5 Connet voltmeter etween ommon engine ground nd Test Point 5 12 Volt Reding* Defetive ignition swith. TEST 6 Chek for voltge etween ommon engine ground nd Test Point 6. No voltge reding: Chek RED wire etween ttery (+) POSITIVE terminl nd Test Point 6. 12 Volt Reding* Chek fuse in RED wire etween Test Points 5 nd 6. Chek for open RED wire etween Test Points 5 nd 6. *Bttery Voltge 90-824052R2 SEPTEMBER 1997 ELECTRICAL - 2B-11

TEST 7. Connet voltmeter etween ommon engine nd Test Point 1.. Turn ignition key to Strt position. No voltge reding: Defetive strter solenoid 12 Volt Reding* Should her solenoid lik: proeed to TEST 8 TEST 8. Reonnet BLACK le (with YELLOW sleeve) to strter solenoid Test Point 1.. Connet voltmeter etween ommon engine ground nd Test Point 7.. Turn ignition key to Strt position. No voltge reding: Chek BLACK le (with YELLOW sleeve) for poor onnetion or open iruit. 12 Volt Reding* If strter motor does not turn, hek strter motor. *Bttery Voltge Strter Removl nd Instlltion REMOVAL CAUTION Disonnet ttery leds from ttery efore removing strter. 1. Disonnet BLACK ground le from strter. 2. Disonnet BLACK (with YELLOW sleeve) le from strter. 3. Remove 4 olts nd upper nd lower strter lmps. Lift strter from engine. e d f - BLACK Ground Cle - BLACK (with YELLOW sleeve) POSITIVE (+) 12- Volt Cle - Upper Mounting Bolts d - Lower Mounting Bolt e - Upper Clmp f - Lower lmp 51840 2B-12 - ELECTRICAL 90-824052R2 SEPTEMBER 1997

INSTALLATION 1. Slide ruer ollrs on strter. 2. If the removed strter ws equipped with sper reple sper on upper ollr.. Remove hex nut nd wshers from POSI- TIVE (+) terminl nd remove POSITIVE rushes nd terminl s n ssemly.. Remove 2 olts seuring NEGATIVE (-) rushes nd rush holder to end p. 11645 - Ruer Collr - Sper (If Equipped) 3. Instll strter to engine with strter lmps. Mke sure tht lk ground le is fstened, long with lower mounting olts. Torque olts to 210 l. in. (23.5 N m). 4. Reonnet yellow le to positive (+) terminl on strter. 5. Reonnet lk ground le to terminl on strter. DISASSEMBLY 1. Remove strter s outlined in Strter Removl nd Instlltion. 2. Remove 2 through olts from strter. e 11656 - Brush Holder - POSITIVE Brushes - NEGATIVE Brushes d - POSITIVE Terminl e - Bolts (Fsten NEGATIVE Brushes nd Holder) 5. Remove rmture (with drive end p) from strter frme. 6. Remove loknut nd remove drive ssemly from rmture shft. d e 11646 - Through Bolts - Commuttor End Cp 3. Tp ommuttor end p to loosen nd remove from frme. Do not lose rush springs. 4. Brush replement is reommended if rushes re pitted, hipped or worn to less thn 0.25 in. (6.4 mm). If neessry, remove rushes s follows: - Hold Armture Shft with Wrenh on Hex Portion of Drive Assemly 90-824052R2 SEPTEMBER 1997 ELECTRICAL - 2B-13

Then remove prts from shft. - Loknut - Sper - Spring d - Drive Assemly e - Drive End Cp f - Armture Shft g - Wsher d e f g Strter Clening, Inspetion nd Testing 11658 CLEANING AND INSPECTION 1. Clen ll strter motor prts. 2. Chek pinion teeth for hips, rks or exessive wer. 3. Reple the drive luth spring nd/or ollr if tension is not dequte or if wer is exessive. 4. Inspet rush holder for dmge or for filure to hold rushes ginst ommuttor. 5. Reple rushes tht re pitted or worn to less thn 1/4 in. (6.4mm) in length. 6. Inspet the rmture ondutor (ommuttor r juntion) for tight onnetion. A loose onnetion (exessive het from prolonged rnking melts solder joints) results in urned ommuttor r. 7. Resurfe nd underut rough ommuttor s follows: CAUTION Do not turn down the ommuttor exessively.. Resurfe the ommuttor nd underut the insultion etween the ommuttor rs 1/32 in. (0.8mm) to the full width of the insultion nd so tht the underut is flt.. Clen the ommuttor slots fter underutting.. Snd the ommuttor lightly with No. 00 sndpper to remove urrs, then len the ommuttor. d. Rehek the rmture on growler for shorts s speified in the following proedure ( Testing ). 8. Open-iruited rmtures often n e repired. The most likely ple for n open iruit is t the ommuttor rs, s result of long rnking periods. Long rnking periods overhet the strter motor so tht solder in the onnetions melts nd is thrown out. The resulting poor onnetions then use ring nd urning of the ommuttor rs. 9. Repir rs, tht re not exessively urned, y resoldering the leds in rs (using rosin flux solder) nd turning down the ommuttor in lthe to remove urned mteril, then underut the mi. 10. Clen out the opper or rush dust from slots etween the ommuttor rs. 11. Chek the rmture for ground. See the following proedure ( Testing ). TESTING Armture Test for Shorts Chek rmture for short iruits y pling on growler nd holding hk sw lde over rmture ore while rmture is rotted. If sw lde virtes, rmture is shorted. Rehek fter lening etween ommuttor rs. If sw lde still virtes, reple rmture. 11669 2B-14 - ELECTRICAL 90-824052R2 SEPTEMBER 1997

Armture Test for Ground 1. Set ohmmeter to (R x 1 sle). Ple one led of ohmmeter on rmture ore or shft nd other led on ommuttor. 2. If meter indites ontinuity, rmture is grounded nd must e repled. Testing Negtive Brushes for Ground Set ohmmeter to (R x1 sle). Ple one led of the ohmmeter on the NEGATIVE rush nd the other led on the end p (re metl). If the meter indites NO ontinuity, reple the NEGATIVE rush. Repet this proedure on the other NEGATIVE rush. 11675 Cheking Positive Brushes nd Terminl Set ohmmeter to (R x 1 sle). Connet meter leds etween POSITIVE rushes. Meter must indite full ontinuity or zero resistne. If resistne is indited, inspet led to rush nd led to POSITIVE terminl solder onnetion. If onnetion nnot e repired, rushes must e repled. - NEGATIVE (-) Brushes - End Cp 11674 - POSITIVE (+) Brushes 11673 90-824052R2 SEPTEMBER 1997 ELECTRICAL - 2B-15

STARTER REASSEMBLY 1. If rushes were removed, reple s follows:. Instll POSITIVE rushes (long with POSI- TIVE terminl) into ommuttor end p.. Instll NEGATIVE rushes (long with rush holder). i d d h d d e f g 11656 - POSITIVE (+)Brushes - NEGATIVE (-) Brushes - Brush Holder d - Bolts (Fsten NEGATIVE Brushes nd Holder) 2. If removed, reinstll prts on rmture shft. Use new loknut nd tighten seurely on end of shft. - End Cp - POSITIVE Brushes - POSITIVE Terminl d - Insulting Bushing e - Wsher f - Split Wsher g - Hex Nut h - Long Brush Led i - Push Led into Slot 11660 d e f g 11658 - Loknut - Sper - Spring d - Drive Assemly e - Drive End Cp f - Armture Shft g - Wsher 3. Lurite helix threds on rmture shft with drop of SAE 10W oil. 4. Lurite ushing in drive end plte with drop of SAE 10W oil. 2B-16 - ELECTRICAL 90-824052R2 SEPTEMBER 1997

5. Position rmture into strter frme. 6. To prevent dmge to rushes nd springs when instlling ommuttor end p, it is reommended tht rush retining tool e mde s shown: 8. Ple springs nd rushes into rush holder nd hold in ple with rush retiner tool. 11661 - Brush Retiner Tool - Bushing (DO NOT over lurite) 9. Instll rmture into strter frme nd lign mth mrks (). Instll ommuttor end p onto strter frme nd lign mth mrks (). Remove rush retiner tool. Instll through olts () nd torque to 70 l. in. (8.0 N m). 18-Guge Sheet Metl METRIC SCALE 3 = 76.2mm 2 = 50.8mm 1-3/4 = 44.5mm 1-11/16 = 42.9mm 3/4 = 19.1mm 1/2 = 12.7mm - Alignment Mrks - Alignment Mrks - Bolts [Torque to 70 l. in. (8.0 N m)] 11648 7. Lurite ushing (loted in ommuttor end p) with one drop of SAE 10W oil. DO NOT over lurite. 90-824052R2 SEPTEMBER 1997 ELECTRICAL - 2B-17

STARTER SOLENOID TEST 1. Disonnet ll wires from solenoid. 2. Use n ohmmeter (R x1 sle) nd onnet meter leds etween solenoid terminls 1 nd 2. 3. Connet 12-volt power supply etween solenoid terminls 3 nd 4. Solenoid should lik nd meter should red 0 ohms (full ontinuity). 4. If meter does not red 0 ohms (full ontinuity), reple solenoid. 1 3 4 2-12-VOLT Supply - VOA Leds 51809 2B-18 - ELECTRICAL 90-824052R2 SEPTEMBER 1997