ELECTRICAL Section 2B - Bttery Chrging System nd Strting System Tle of Contents Specifictions........................... 2B-1 Specil Tools........................... 2B-2 Bttery Chrging System Description...... 2B-3 Bttery Chrging System Trouleshooting.. 2B-3 Generl Trouleshooting.............. 2B-3 Alterntor System.................... 2B-4 Trouleshooting Alterntor System..... 2B-4 Strter System....................... 2B-7 Incorporting Bttery Isoltor With V-6 40 Amp Chrging System..................... 2B-8 Specifictions System Wired for Split Output.......... 2B-9 System Wired for 40 Ampere Output to Isoltor.................... 2B-10 Flywheel/Strter Assemly............... 2B-11 Strter Assemly........................ 2B-12 Strter Circuit Trouleshooting Flow Chrt 2B-13 Strter Removl nd Instlltion........ 2B-14 Strter Clening, Inspection nd Testing. 2B-17 2 B Strter Drw (No Lod) Strter Drw (Under Lod) Bttery Rting Alterntor Output 40 Amperes 175 Amperes 670 Mrine Crnking Amps (MCA) or 520 Cold Crnking Amps (CCA) 12 Amperes @ 3000 RPM 90-877837 NOVEMBER 1999 Pge 2B-1
Specil Tools Multi Meter DVA Tester 91-99750A1 DMT 2000 Digitl Tchometer/Multi-meter (91-854009A1) Description Hydrometer Ammeter Prt Numer Otin Loclly Otin Loclly Pge 2B-2 90-877837 NOVEMBER 1999
Bttery Chrging System Description BATTERY CHARGING SYSTEM AND STARTING SYSTEM The ttery chrging system components re the flywheel permnent mgnets, sttor, voltge regultor/rectifier nd ttery. The rotting permnent mgnets induce n lternting current (AC) in the sttor coils. The AC current is rectified to direct current (DC) y the voltge regultor/rectifier. The DC output from the voltge regultor/rectifier is used to chrge the ttery. The voltge regultor/rectifier lso senses the ttery voltge s mesure of the ttery s stte of chrge nd therey regultes the DC current flow to the ttery. In this mnner, the ttery chrge is mintined nd the ttery is protected from n overchrge condition. c d -Sttor -Strter Solenoid c -To Tchometer d-voltge Regultor/Rectifier e -12 Volt Bttery e 51806 Bttery Chrging System Trouleshooting Generl Trouleshooting A fult in the ttery chrging system will usully cuse the ttery to ecome UNDER- CHARGED. A defective VOLTAGE REGULATOR my lso llow the system to OVER- CHARGE the ttery. If prolem exists in the chrging system, visully check the following: 1. Check for correct ttery polrity [RED cle to (+) POSITIVE ttery terminl]. 2. Check for loose or corroded ttery terminls. 3. Check condition of the ttery. 4. Visully inspect ll wiring etween sttor nd ttery for cuts, chfing nd disconnected, loose or corroded connections. 5. Excessive electricl lod (from too mny ccessories) will cuse ttery to run down, even if the system is operting correctly. If the system is still OVERCHARGING the ttery, the VOLTAGE REGULATOR is most likely defective nd should e replced. If the ttery is UNDERCHARGED, proceed with REGULATOR, STATOR, nd RECTIFIER tests, following. 90-877837 NOVEMBER 1999 Pge 2B-3
Alterntor System STATOR TEST (ALTERNATOR COILS ONLY) NOTE: Sttor cn e tested without removing from engine. 1. Disconnect 2 YELLOW sttor leds from ullet connectors to voltge regultor/rectifier. 2. Use n ohmmeter nd perform the following test: 15 AMP SYSTEM Test Leds To- Resistnce (Ohms) Scle Reding Connect test leds etween 2 YELLOW sttor leds.25-.45* R x 1 RED test led to 1 YELLOW sttor led, nd BLACK test led to engine ground if sttor is mounted or to steel frme of sttor (if off engine) No Continuity R x 1000 40 AMP SYSTEM Test Leds To- Resistnce (Ohms) Scle Reding Connect test leds etween 2 short YELLOW nd 2 long YEL- LOW sttor leds.25-.45* R x 1 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) No Continuity R x 1000 * Resistnce of these windings generlly is less thn one ohm. A reding, tht resemles short, is cceptle. Copper wire is n excellent conductor ut will hve noticele differences from cold to hot. Resonle vrition from specified reding is cceptle. 3. If meter redings re other thn specified, replce sttor ssemly Refer to sttor ssemly replcement in Section 2A. Trouleshooting Alterntor System WARNING Before connecting or disconnecting ny electricl connection, ttery cles MUST BE REMOVED from ttery to prevent possile personl injury or dmge to equipment. IMPORTANT: The chrging system my e connected to one or more tteries during these tests. However, these tteries MUST BE fully chrged. These tteries MUST NOT BE connected to ny other chrging source. IMPORTANT: Check tht ll connections re tight prior to strting tests. Ensure tht the ttery posts nd terminls re clen nd mking good contct. Verify with test equipment tht wiring hrnesses re not t fult. Pge 2B-4 90-877837 NOVEMBER 1999
DETERMINING CAUSE OF PROBLEM BATTERY CHARGING SYSTEM AND STARTING SYSTEM 1. Connect outord ttery leds to ttery(s) tht re known to e in good condition nd re fully chrged. 2. Check voltge t ttery(s) with n nlog volt meter. Digitl voltmeters re not recommended s they my e inccurte due to interference from ignition system. 3. Strt engine 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 increse from previously checked ttery voltge vlues, refer to NO OUTPUT, following, for trouleshooting procedures. If voltge exceeds 16 volts nd DOES NOT return down to nd stilize t 14.5 volts, refer to CONSTANT HIGH OUTPUT, following for trouleshooting procedures. PROBLEM: CONSTANT HIGH OUTPUT 1. Remove flywheel nd visully inspect sttor. Discolortion of one or more poles, or urned windings will require replcement of sttor. 2. If no visul defects of sttor re found, reinstll flywheel. Temporrily instll mmeter (of sufficient size to crry 50 mperes) in series with the RED output led (MALE ullet led) of the regultor nd the strter solenoid. 15 AMP SYSTEM 3. Remove 1 YELLOW sttor led from ullet connector. Run engine t 1000-2000 RPM. Any output current indictes sttor is shorted to ground. Replce sttor. 4. If there is no output with YELLOW led disconnected, the regultor is defective. 40 AMP SYSTEM 5. Remove 1 short nd 2 long YELLOW sttor leds from their ullet connectors. Run engine t 1000-2000 RPM. If no output current is oserved, disconnect 2 short YELLOW leds nd 1 long YELLOW led. Repet the test with the second long YELLOW led connected. Any output indictes sttor is shorted to ground. Replce sttor. 6. If there is no output with either short or long YELLOW leds disconnected, the regultors re defective. PROBLEM: NO OUTPUT IMPORTANT: Regultor(s) MUST hve good ground. Verify clen contct surfce exists etween regultor cse, powerhed nd ttching hrdwre. 1. Check voltge on either RED wire to regultor (ullet connectors). These leds must indicte ttery voltge when the key is in the RUN position. If ttery voltge is NOT present, the key switch or wiring etween the key switch nd the test point is defective. Refer to Wiring Digrm, Section 2A. 2. Connect n AC voltmeter to YELLOW led ullet connector on the regultor. If the AC voltge t idle or ove is greter thn 16 VAC, the regultor is defective. NOTE: The tchometer signl is provided y the regultor. It is possile to still hve n ccurte tchometer signl with defective regultor. REGULATION VOLTAGE CHECK NOTE: Bttery must e fully chrged efore testing regultion voltge. A low ttery will not llow n ccurte reding of regultion voltge. 1. Turn on ll electricl ccessories nd crnk engine for 20 seconds with the ignition lnyrd switch turned off. This will dischrge ttery slightly. 90-877837 NOVEMBER 1999 Pge 2B-5
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 reduce the possiility of erroneous redings from ignition noise. VOLTAGE REGULATOR TEST (USING OHM METER) IMPORTANT: Mke sure meter is zeroed y shorting meter leds together fter chnging selector kno to pproprite setting. The meter reding must red 0 Ohms. IMPORTANT: The following regultor tests should e performed s soon s possile fter suspected regultor filure. A cold regultor my test GOOD when in fct it is defective when wrm. Disconnect ll voltge regultor wires. Using Ohm meter, perform ech Ohms test listed elow: Test Leds To- Resistnce (Ohms) Scle Diode Check: Connect NEGATIVE ( ) ohm led to either YELLOW led. Connect POSITIVE (+) test 100-400 R x 10 led to thick RED led. Diode Check: Connect NEGATIVE ( ) ohm led to thick RED led. Connect POSITIVE (+) ohm led to either YELLOW led. 40K to R x 1K SCR Checks: Connect NEGATIVE ( ) ohm led to either YELLOW led. Connect POSITIVE (+) ohm led to cse ground. Tchometer Circuit Check: Connect NEGATIVE ( ) ohm led to cse ground. Connect POSITIVE (+) ohm led to GRAY led. REMOVAL OF VOLTAGE REGULATOR 10K to 10K to 30K R x 1K R x 1K 1. Disconnect ll voltge regultor wires. Remove two screws securing voltge regultor to ignition plte. -Voltge Regultor/Rectifier 2. Remove voltge regultor/rectifier from powerhed. Pge 2B-6 90-877837 NOVEMBER 1999
INSTALLATION OF VOLTAGE REGULATOR/RECTIFIER Strter System BATTERY CHARGING SYSTEM AND STARTING SYSTEM 1. Position regultor over ignition plte. Secure with two screws. 2. Connect YELLOW, RED nd GRAY (s required) leds to their respective ullet connectors. STARTER SYSTEM COMPONENTS DESCRIPTION 1. Bttery 2. Strter Solenoid 3. Neutrl Strt Switch 4. Strter Motor 5. Ignition Switch The function of the strting system is to crnk the engine. The ttery supplies electricity to ctivte the strter motor. When the ignition switch is turned to the START position, the strter solenoid is energized nd completes the strter circuit etween the ttery nd strter. The neutrl strt switch opens the strter circuit when the shift control lever is not in neutrl thus preventing ccidentl strting when the engine is in ger. CAUTION The strter motor my e dmged if operted continuously. DO NOT operte continuously for more thn 30 seconds. Allow 2 minute cooling period etween strting ttempts. 90-877837 NOVEMBER 1999 Pge 2B-7
TROUBLESHOOTING THE STARTER CIRCUIT Before eginning the trouleshooting flow chrt, verify the following conditions: 1. Confirm tht ttery is fully chrged. 2. Check tht control lever is in NEUTRAL position. 3. Check terminls for corrosion nd loose connections. 4. Check cles nd wiring for fryed nd worn insultion. 5. Check 20 mp fuse. Loction of Test Points (clled out in flow chrt) re numered elow. g f e c d -Strter Solenoid -Strter c -Neutrl Strt Switch d-ignition Switch e -20 Ampere Fuse f -Strter Solenoid g-bttery Incorporting Bttery Isoltor With V-6 40 Amp Chrging System A ttery isoltor will llow the chrging system to chrge oth the strting ttery nd n uxiliry ttery t the sme time while preventing ccessories, connected to the uxiliry ttery, from drwing power from the crnking ttery. 1. Instll the isoltor s prescried y the mnufcturer. IMPORTANT: After electricl connections re mde, cot ll terminl connections using Quicksilver Liquid Neoprene (92-25711) to void corrosion. Pge 2B-8 90-877837 NOVEMBER 1999
2. Using BATTERY ISOLATOR HARNESS KIT 84-815366A3, chrging system cn e wired to provide either 20 mps to uxiliry ttery nd 20 mps to crnking ttery or 40 mps to isoltor. System Wired for Split Output 20 AMPERES TO AUXILIARY BATTERY; 20 AMPERES TO CRANKING BATTERY d c e f g h -Strter Solenoid -RED Leds Engine Hrness from Upper Regultor to Strt Solenoid c -Disconnect (nd discrd) 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 90-877837 NOVEMBER 1999 Pge 2B-9
System Wired for 40 Ampere Output to Isoltor IMPORTANT: After electricl connections re mde, cot ll terminl connections using Quicksilver Liquid Neoprene (92-25711) to void corrosion. k j h c d i h e f g -Strter Solenoid -RED Led to Strter Solenoid c -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 Pge 2B-10 90-877837 NOVEMBER 1999
Flywheel/Strter Assemly BATTERY CHARGING SYSTEM AND STARTING SYSTEM TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 DECAL-Sport Jet 175XR 2 2 1 PLUG 3 1 COVER KIT-Flywheel 4 2 WASHER 5 2 SCREW (.190-32 x.380) 6 1 MARKER-Timing 7 1 PLUG 8 1 NUT (.625-18) 120 163 9 1 WASHER 10 1 FLYWHEEL ASSEMBLY 11 4 SCREW (#10-32 x 1.00) 12 4 LOCKWASHER (#10) 13 1 STATOR ASSEMBLY 14 1 TRIGGER PLATE ASSEMBLY 15 2 COLLAR-Strter Cp 16 1 DECAL-Strt In Ger 17 1 DECAL-High Voltge 18 1 WIRE ASSEMBLY (12.500 in.) (BLACK) 19 1 NUT (.250-20) 20 1 LOCKWASHER (.250) 21 1 STARTER ASSEMBLY 22 1 BOOT (Red)-Strter Led 23 1 SCREW W/ LOCKWASHER (.250-20 x.625) 24 1 WIRE ASSEMBLY (6.00 in.) (BLACK) 25 2 STOP (Ruer) 90-877837 NOVEMBER 1999 Pge 2B-11
Strter Assemly 2 8 3 5 4 6 1 7 14 13 9 9 8 11 10 9 12 TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 STARTER ASSEMBLY 2 1 DRIVE KIT-Pinion 3 1 PINION ASSEMBLY-Drive 4 1 CAP ASSEMBLY-Drive End 5 2 THRU BOLT 6 2 O RING-Thru Bolt 7 1 ARMATURE 8 2 O RING-Strter Frme 9 1 BRUSH/SPRING KIT 10 2 SCREW-Brush Holder 11 1 HOLDER-Brush 12 1 CAP-Com End 13 1 WASHER-Insultor-Brush Post 14 1 NUT-Brush Post Pge 2B-12 90-877837 NOVEMBER 1999
Strter Circuit Trouleshooting Flow Chrt BATTERY CHARGING SYSTEM AND STARTING SYSTEM Strter Motor Does Not Turn SAFETY WARNING: Disconnect YELLOW (strter motor) cle from strter solenoid test point 1 BEFORE mking tests 1-thru-7 to prevent unexpected engine crnking. TEST 1 Use n ohmmeter (Rx1 scle) nd connect meter leds etween NEGATIVE (-) ttery post nd common powerhed ground. No Continuity Indicted - There is n open circuit in the BLACK NEGATIVE (-) ttery cle etween the NEGATIVE (-) ttery post nd the powerhed. Check cle for loose or corroded connections. Check cle for open. Continuity Indicted Proceed to TEST 2 No voltge reding: proceed to TEST 3. Test 2. Disconnect BLACK ground wire(s) from Test Point 2.. Connect voltmeter etween common engine ground nd Test Point 2. c. Turn ignition key to Strt position. TEST 3. Reconnect BLACK ground wire.. Connect voltmeter etween common engine ground nd Test Point 3. c. Turn ignition key to Strt position. 12 Volt Reding* Check BLACK ground wire for poor connection or open circuit. Reconnect ground wire to strter solenoid. Proceed to TEST 7. No voltge reding: Proceed to TEST 4 12 Volt Reding Defective strter solenoid No voltge reding: Proceed to TEST 5 TEST 4. Connect voltmeter etween common engine ground nd Test Point 4.. Turn ignition key to Strt position. 12 Volt Reding* Neutrl strt switch is open or YELLOW/RED wire is open etween Test Points 4 nd 3. No voltge reding: Proceed to Test 6. TEST 5 Connect voltmeter etween common engine ground nd Test Point 5 12 Volt Reding* Defective ignition switch. TEST 6 Check for voltge etween common engine ground nd Test Point 6. No voltge reding: Check RED wire etween ttery (+) POSITIVE terminl nd Test Point 6. 12 Volt Reding* Check fuse in RED wire etween Test Points 5 nd 6. Check for open RED wire etween Test Points 5 nd 6. *Bttery Voltge 90-877837 NOVEMBER 1999 Pge 2B-13
TEST 7. Connect voltmeter etween common engine nd Test Point 1.. Turn ignition key to Strt position. No voltge reding: Defective strter solenoid 12 Volt Reding* Should her solenoid click: proceed to TEST 8 TEST 8. Reconnect BLACK cle (with YELLOW sleeve) to strter solenoid Test Point 1.. Connect voltmeter etween common engine ground nd Test Point 7. c. Turn ignition key to Strt position. No voltge reding: Check BLACK cle (with YELLOW sleeve) for poor connection or open circuit. 12 Volt Reding* If strter motor does not turn, check strter motor. *Bttery Voltge Strter Removl nd Instlltion REMOVAL CAUTION Disconnect ttery leds from ttery efore removing strter. 1. Disconnect BLACK ground cle from strter. 2. Disconnect BLACK (with YELLOW sleeve) cle from strter. 3. Remove 4 olts nd upper nd lower strter clmps. Lift strter from engine. -BLACK (with YELLOW sleeve) POSITIVE (+) 12- -BLACK Ground Cle Pge 2B-14 90-877837 NOVEMBER 1999
INSTALLATION 1. Slide ruer collrs on strter. 2. If the removed strter ws equipped with spcer replce spcer on upper collr. DISASSEMBLY 11645 -Ruer Collr -Spcer (If Equipped) 3. Instll strter to engine with strter clmps. Mke sure tht lck ground cle is fstened, long with lower mounting olts. Torque olts to 210 l. in. (23.5 N m). 4. Reconnect yellow cle to positive (+) terminl on strter. 5. Reconnect lck ground cle to terminl on strter. 1. Remove strter s outlined in Strter Removl nd Instlltion. 2. Remove 2 through olts from strter. 11646 -Through Bolts -Commuttor End Cp 3. Tp commuttor end cp to loosen nd remove from frme. Do not lose rush springs. 4. Brush replcement is recommended if rushes re pitted, chipped or worn to less thn 0.25 in. (6.4 mm). If necessry, remove rushes s follows:. Remove hex nut nd wshers from POSITIVE (+) terminl nd remove POSITIVE rushes nd terminl s n ssemly. 90-877837 NOVEMBER 1999 Pge 2B-15
. Remove 2 olts securing NEGATIVE (-) rushes nd rush holder to end cp. c e e c 11656 -Brush Holder -POSITIVE Brushes c -NEGATIVE Brushes d-positive Terminl e -Bolts (Fsten NEGATIVE Brushes nd Holder) 5. Remove rmture (with drive end cp) from strter frme. 6. Remove locknut nd remove drive ssemly from rmture shft. d -Hold Armture Shft with Wrench on Hex Portion of Drive Assemly Pge 2B-16 90-877837 NOVEMBER 1999
Then remove prts from shft. c d e f g -Locknut -Spcer c -Spring d-drive Assemly e -Drive End Cp f -Armture Shft g-wsher Strter Clening, Inspection nd Testing CLEANING AND INSPECTION 11658 1. Clen ll strter motor prts. 2. Check pinion teeth for chips, crcks or excessive wer. 3. Replce the drive clutch spring nd/or collr if tension is not dequte or if wer is excessive. 4. Inspect rush holder for dmge or for filure to hold rushes ginst commuttor. 5. Replce rushes tht re pitted or worn to less thn 1/4 in. (6.4mm) in length. 6. Inspect the rmture conductor (commuttor r junction) for tight connection. A loose connection (excessive het from prolonged crnking melts solder joints) results in urned commuttor r. 7. Resurfce nd undercut rough commuttor s follows: CAUTION Do not turn down the commuttor excessively.. Resurfce the commuttor nd undercut the insultion etween the commuttor rs 1/32 in. (0.8mm) to the full width of the insultion nd so tht the undercut is flt.. Clen the commuttor slots fter undercutting. c. Snd the commuttor lightly with No. 00 sndpper to remove urrs, then clen the commuttor. d. Recheck the rmture on growler for shorts s specified in the following procedure ( Testing ). 8. Open-circuited rmtures often cn e repired. The most likely plce for n open circuit is t the commuttor rs, s result of long crnking periods. Long crnking periods overhet the strter motor so tht solder in the connections melts nd is thrown out. The resulting poor connections then cuse rcing nd urning of the commuttor rs. 9. Repir rs, tht re not excessively urned, y resoldering the leds in rs (using rosin flux solder) nd turning down the commuttor in lthe to remove urned mteril, then undercut the mic. 10. Clen out the copper or rush dust from slots etween the commuttor rs. 11. Check the rmture for ground. See the following procedure ( Testing ). 90-877837 NOVEMBER 1999 Pge 2B-17
TESTING Armture Test for Shorts Check rmture for short circuits y plcing on growler nd holding hck sw lde over rmture core while rmture is rotted. If sw lde virtes, rmture is shorted. Recheck fter clening etween commuttor rs. If sw lde still virtes, replce rmture. 11669 Armture Test for Ground 1. Set ohmmeter to (R x 1 scle). Plce one led of ohmmeter on rmture core or shft nd other led on commuttor. 2. If meter indictes continuity, rmture is grounded nd must e replced. Checking Positive Brushes nd Terminl 11675 Pge 2B-18 90-877837 NOVEMBER 1999
Set ohmmeter to (R x 1 scle). Connect meter leds etween POSITIVE rushes. Meter must indicte full continuity or zero resistnce. If resistnce is indicted, inspect led to rush nd led to POSITIVE terminl solder connection. If connection cnnot e repired, rushes must e replced. 11673 -POSITIVE (+) Brushes Testing Negtive Brushes for Ground Set ohmmeter to (R x1 scle). Plce one led of the ohmmeter on the NEGATIVE rush nd the other led on the end cp (re metl). If the meter indictes NO continuity, replce the NEGATIVE rush. Repet this procedure on the other NEGATIVE rush. -NEGATIVE (-) Brushes -End Cp 11674 90-877837 NOVEMBER 1999 Pge 2B-19
STARTER REASSEMBLY 1. If rushes were removed, replce s follows:. Instll POSITIVE rushes (long with POSITIVE terminl) into commuttor end cp. i d h d e f c g -End Cp -POSITIVE Brushes c -POSITIVE Terminl d-insulting Bushing e -Wsher f -Split Wsher g-hex Nut h-long Brush Led i -Push Led into Slot 11660 Pge 2B-20 90-877837 NOVEMBER 1999
. Instll NEGATIVE rushes (long with rush holder). BATTERY CHARGING SYSTEM AND STARTING SYSTEM c d d 11656 -POSITIVE (+)Brushes -NEGATIVE (-) Brushes c -Brush Holder d-bolts (Fsten NEGATIVE Brushes nd Holder) 2. If removed, reinstll prts on rmture shft. Use new locknut nd tighten securely on end of shft. c d e f g -Locknut -Spcer c -Spring d-drive Assemly e -Drive End Cp f -Armture Shft g-wsher 3. Luricte helix threds on rmture shft with drop of SAE 10W oil. 4. Luricte ushing in drive end plte with drop of SAE 10W oil. 5. Position rmture into strter frme. 11658 90-877837 NOVEMBER 1999 Pge 2B-21
6. To prevent dmge to rushes nd springs when instlling commuttor end cp, it is recommended tht rush retining tool e mde s shown: 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 7. Luricte ushing (locted in commuttor end cp) with one drop of SAE 10W oil. DO NOT over luricte. Pge 2B-22 90-877837 NOVEMBER 1999
8. Plce springs nd rushes into rush holder nd hold in plce with rush retiner tool 11661 -Brush Retiner Tool -Bushing (DO NOT over luricte) 9. Instll rmture into strter frme nd lign mtch mrks (). Instll commuttor end cp onto strter frme nd lign mtch mrks (). Remove rush retiner tool. Instll through olts (c) nd torque to 70 l. in. (8.0 N m) c c -Alignment Mrks -Alignment Mrks c -Bolts [Torque to 70 l. in. (8.0 N m)] 11648 90-877837 NOVEMBER 1999 Pge 2B-23
STARTER SOLENOID TEST 1. Disconnect ll wires from solenoid. 2. Use n ohmmeter (R x1 scle) nd connect meter leds etween solenoid terminls 1 nd 2. 3. Connect 12-volt power supply etween solenoid terminls 3 nd 4. Solenoid should click nd meter should red 0 ohms (full continuity). 4. If meter does not red 0 ohms (full continuity), replce solenoid. -12-VOLT Supply -VOA Leds 51809 Pge 2B-24 90-877837 NOVEMBER 1999