ELECTRICAL Section 2B Chrging & Strting System Tle of Contents Specifictions........................... 2B-2 Specil Tools........................... 2B-3 Bttery Cle Size...................... 2B-4 Replcement Prts...................... 2B-4 Recommended Bttery................... 2B-4 Bttery................................. 2B-5 Precutions.......................... 2B-5 Chrging Dischrged Bttery............ 2B-5 Winter Storge of Btteries............... 2B-6 Flywheel Removl nd Instlltion......... 2B-7 Removl............................ 2B-7 Instlltion........................... 2B-8 Notes:................................. 2B-9 Flywheel/Alterntor...................... 2B-10 System Components.................... 2B-12 Precutions.......................... 2B-12 Alterntor Description.................... 2B-13 Dignosis of Alterntor System on Engine.. 2B-13 Alterntor System Circuitry Test........... 2B-14 Output Circuit........................ 2B-14 Sensing Circuit....................... 2B-15 Voltge Output....................... 2B-16 Current Output....................... 2B-17 Repir................................. 2B-18 Removl............................ 2B-18 Instlltion............................. 2B-19 Alterntor Belt Tension Adjustment........ 2B-20 Strter System.......................... 2B-21 Strter Motor Amperes Drw........... 2B-21 Strter System Components........... 2B-21 Description.......................... 2B-21 Strter Motor (Model Yer 2000) (Centrifugl Bendix)..................... 2B-22 Strter Motor (Model Yer 2001) (Solenoid Driven Bendix)................. 2B-24 Trouleshooting the Centrifugl Bendix Strter Circuit........................... 2B-26 Strter Circuit Trouleshooting Flow Chrt (Centrifugl Bendix)..................... 2B-27 Trouleshooting the Solenoid Driven Bendix Strter Circuit.................... 2B-29 Strter Circuit Trouleshooting Flow Chrt (Solenoid Driven Bendix)................. 2B-30 Strter Removl nd Instlltion (2000 Model) (Centrifugl Bendix)...................... 2B-32 Removl............................ 2B-32 Instlltion........................... 2B-32 Disssemly............................ 2B-33 Strter Clening, Inspection nd Testing... 2B-35 Clening nd Inspection.................. 2B-35 Testing.............................. 2B-35 Ressemly (Centrifugl Bendix).......... 2B-37 Strter Solenoid Test.................. 2B-39 Strter Removl nd Instlltion (2001 Model) (Solenoid Driven Bendix)................. 2B-40 Removl............................ 2B-40 Instlltion........................... 2B-41 Disssemly (Solenoid Driven Bendix Strter) 2B-42 Clening nd Inspection.................. 2B-45 Ressemly (Solenoid Driven Bendix Strter) 2B-46 Commnder 2000 Key Switch Test........ 2B-50 2 B 90-859769R1 DECEMBER 2000 Pge 2B-1
Specifictions CHARGING SYSTEM STARTING SYSTEM Alterntor Output (Regulted) Brush Length Voltge Output Regultor Current Drw Model Yer 2000 Electric Strt Strter Drw (Under Lod) Strter Drw (No Lod) Minimum Brush Length 32-38 Amperes @ 2000 RPM @ Bttery 52-60 Amperes @ 2000 RPM @ Alterntor Std Exposed Length: 0.413 in. (10.5 mm) Min. Exposed Length: 0.059 in. (1.5 mm) 13.5 to 15.1 Volts 0.15 ma (Ign. Switch Off) 30.0 ma (Ign. Switch On) 210 Amperes 30 Amperes 0.25 in. (65.4 mm) Model Yer 2001 Electric Strt Strter Drw (Under Lod) Strter Drw (No Lod) Minimum Brush Length Bttery Rting 170 Amperes 60 Amperes 0.25 in. (65.4 mm) 1000 (Minimum) Mrine Crnking Amps (MCA) 750 (Minimum) Cold Crnking Amps (CCA) 105 Amp Hour Pge 2B-2 90-859769R1 DECEMBER 2000
Specil Tools 1. Volt/Ohm Meter 91-99750A1or DMT 2000 Digitl Tchometer Multimeter 91-854009A1 -Volt/Ohm Meter 91-99750A1 -DMT 2000 Digitl Tchometer Multimeter 91-854009A1 2. Ammeter (60 Ampere minimum) (Otin loclly) 3. Flywheel Holder 91-52344 4. Protector Cp 91-24161 (Used with Puller 91-73687A1) 54964 5. Flywheel Puller 91-73687A1 or 91-849154T1 -Puller 91-73687A1 -Puller 91-849154T1 90-859769R1 DECEMBER 2000 Pge 2B-3
Bttery Cle Size If stndrd (originl) ttery cles re replced with longer cles, the wire guge size must increse. See chrt elow for correct wire guge size. Î Wire Gge Size Bttery Cle Length Bttery Cle Wire Gge Size Mercury/Mriner Outords Bttery Cle Length 8 ft. 2.4m 9 ft. 2.7m 10ft. 3.0m 11ft. 3.4m 12ft. 3.7m 13ft. 4.0m 14ft. 4.3m 15ft. 4.6m 16ft. 4.9m 17ft. 5.2m 18ft. 5.5m 19ft. 5.8m 20ft. 6.1m 21ft. 6.4m 22ft. 6.7m 23ft. 7.0m 24ft. 7.3m Models Wire Gge Size No. SAE 6-25 Hp #8* #8 #6 #6 #6 #6 #4 #4 #4 #4 #4 #4 #4 #4 #2 #2 #2 30-115 Hp 125-250 Hp (except DFI) DFI Models #6* #4 #4 #4 #4 #4 #2 #2 #2 #2 #2 #2 #2 #2 #0 #0 #0 #6* #6 #4 #4 #4 #4 #4 #4 #2 #2 #2 #2 #2 #2 #2 #4* #2 #2 #2 #2 #2 #2 #2 #2 #2 #0 #0 #0 * = Stndrd (originl) Cle Length nd wire gge size. Replcement Prts WARNING Electricl, ignition nd fuel system components on your Mercury/Mriner outord re designed nd mnufctured to comply with U. S. Cost Gurd Rules nd Regultions to minimize risks of fire nd explosions. Use of replcement electricl, ignition or fuel system components, which do not comply with these rules nd regultions, could result in fire or explosion hzrd nd should e voided. Recommended Bttery A 12 volt mrine ttery with minimum Cold Crnking mperge rting of 750 mperes or 1000 (minimum) Mrine Crnking mperes should e used. Pge 2B-4 90-859769R1 DECEMBER 2000
Bttery Precutions CAUTION If ttery cid comes in contct with skin or eyes, wsh skin immeditely with mild sop. Flush eyes with wter immeditely nd see doctor. When chrging tteries, n explosive gs mixture forms in ech cell. Prt of this gs escpes 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 chrged. Sprks or flmes cn ignite this gs nd cuse n internl explosion which my shtter the ttery. The following precutions should e oserved to prevent n explosion. 1. DO NOT smoke ner tteries eing chrged or which hve een chrged very recently. 2. DO NOT rek live circuits t terminls of tteries ecuse sprk usully occurs t the point where live circuit is roken. Alwys e creful when connecting or disconnecting cle clmps on chrgers. Poor connections re common cuse of electricl rcs which cuse explosions. 3. DO NOT reverse polrity of ttery terminl to cle connections. Chrging Dischrged Bttery WARNING Hydrogen nd oxygen gses re produced during norml ttery opertion or chrging. Sprks or flme cn cuse this mixture to ignite nd explode, if they re rought ner the vent openings. Sulphuric cid in ttery cn cuse serious urns, if spilled on skin or in eyes. Flush or wsh wy immeditely with cler wter. The following sic rule pplies to ny ttery chrging sitution: 1. Any ttery my e chrged t ny rte (in mperes) or s long s spewing of electrolyte (from violent gssing) does not occur nd for s long s electrolyte temperture does not exceed 125 F (52 C). If spewing of electrolyte occurs, or if electrolyte temperture exceeds 125 F, chrging rte (in mperes) must e reduced or temporrily hlted to void dmge to the ttery. 2. Bttery is fully chrged when, over 2-hour period t low chrging rte (in mperes), ll cells re gssing freely (not spewing liquid electrolyte), nd no chnge in specific grvity occurs. Full chrge specific grvity is 1.260-1.275, corrected for electrolyte temperture with electrolyte level t 3/16 in. (4.8 mm) over plte, unless electrolyte loss hs occurred (from ge or over-filling) in which cse specific grvity reding will e lower. For most stisfctory chrging, lower chrging rtes in mperes re recommended. 3. If, fter prolonged chrging, specific grvity of t lest 1.230 on ll cells cnnot e reched, ttery is not in optimum condition nd will not provide optimum performnce; however, it my continue to provide dditionl service, if it hs performed stisfctorily in the pst. 90-859769R1 DECEMBER 2000 Pge 2B-5
4. To check ttery voltge while crnking engine with electric strting motor, plce 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 crnking, the ttery is wek nd should e rechrged or replced. Winter Storge of Btteries Bttery compnies re not responsile for ttery dmge either in winter storge or in deler stock if the following instructions re not oserved: 1. Remove ttery from its instlltion s soon s possile nd remove ll grese, sulfte nd dirt from top surfce y running wter over top of ttery. Be sure, however, tht vent cps re tight eforehnd, nd low off ll excess wter thoroughly with compressed ir. Check wter level, mking sure tht pltes re covered. 2. When dding distilled wter to ttery, e extremely creful not to fill more thn 3/16 in. (4.8 mm) ove perforted ffles inside ttery. Bttery solution or electrolyte expnds from het cused y chrging. Overfilling ttery will cuse electrolyte to overflow (if filled eyond 3/16 ove ffles). 3. Grese terminl olts well with 2-4-C Mrine Luricnt nd store ttery in COOL- DRY plce. Remove ttery from storge every 30-45 dys, check wter level nd put on chrge for 5 or 6 hours t 6 mperes. DO NOT FAST CHARGE. 4. If specific grvity drops elow 1.240, check ttery for reson nd rechrge. When grvity reches 1.260, discontinue chrging. To check specific grvity, use hydrometer, which cn e purchsed loclly. 5. Repet preceding chrging procedure every 30-45 dys, s long s ttery is in storge, for est possile mintennce during inctive periods to ensure good servicele ttery in spring. When redy to plce ttery ck in service, remove excess grese from terminls ( smll mount is desirle on terminls t ll times), rechrge gin s necessry nd reinstll ttery. Pge 2B-6 90-859769R1 DECEMBER 2000
Flywheel Removl nd Instlltion Removl 1. Remove flywheel cover from engine. WARNING Engine could possily strt when turning flywheel during removl nd instlltion; therefore, disconnect (nd isolte) sprk plug leds from sprk plugs to prevent engine from strting. 2. Disconnect sprk plug leds from sprk plugs. 3. While holding flywheel with flywheel holder (91-52344), remove flywheel nut nd wsher. -Flywheel Holder (91-25344) 57930 4. Instll crnkshft Protector Cp (91-24161) on end of crnkshft, then instll Flywheel Puller (91-73687A2) into flywheel. 90-859769R1 DECEMBER 2000 Pge 2B-7
5. Hold flywheel tool with wrench while tightening olt down on protector cp. Tighten olt until flywheel comes free. -Flywheel Puller (91-73687A2) 57804 Instlltion NOTE: Neither het or hmmer should e used on flywheel to id in removl s dmge to flywheel my result. 6. Remove flywheel. Inspect flywheel for crcks or dmge. IMPORTANT: Clen flywheel/crnkshft tper with solvent nd ssemle dry. 1. Instll flywheel. 2. Instll flywheel wsher nd nut. 3. Hold flywheel with Flywheel Holder (91-52344). Torque nut to 125 l-ft (169.5 Nm). -Flywheel Holder (91-52344) 57805 Pge 2B-8 90-859769R1 DECEMBER 2000
Notes: 90-859769R1 DECEMBER 2000 Pge 2B-9
Flywheel/Alterntor 10 15 16 TO BLOCK 14 Pge 2B-10 90-859769R1 DECEMBER 2000
Flywheel/Alterntor TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 ALTERNATOR 2 1 SPRING 3 1 BEARING 4 1 BELT TENSIONER 5 1 BUSHING 6 1 SCREW (M10 x 45) 200 16.5 22.6 7 1 PULLEY 8 1 SCREW (M10 x 35) 300 25 34 9 1 BELT 10 1 FLYWHEEL 11 1 NUT (.625-18) 125 169 12 1 WASHER 13 1 PLUG 14 1 NUT 36 4.0 15 1 CABLE 16 1 WASHER ANTI ROTATION 90-859769R1 DECEMBER 2000 Pge 2B-11
System Components The ttery chrging system consists of the lterntor, ttery, ignition switch, strter solenoid nd the wiring which connects these components. c d -Alterntor -Bttery c -20 Ampere Fuse d-strter Solenoid To 51708 Precutions The following precutions must e oserved when working on the lterntor system. Filure to oserve these precutions my result in serious dmge to the lterntor system. 1. Do not ttempt to polrize the lterntor. 2. Do not short cross or ground ny of the terminls on the lterntor, except s specificlly instructed. 3. Never disconnect the lterntor output led, regultor hrness or ttery cles when the lterntor is eing driven y the engine. 4. Alwys remove NEGATIVE ( ) ttery cle from ttery efore working on lterntor system. 5. When instlling ttery, e sure to connect the NEGATIVE ( ) (GROUNDED) ttery cle to NEGATIVE ( ) ttery terminl nd the POSITIVE (+) ttery cle to POSI- TIVE (+) ttery terminl. 6. When using chrger or ooster ttery, connect it in prllel with existing ttery (POSITIVE to POSITIVE; NEGATIVE to NEGATIVE). Pge 2B-12 90-859769R1 DECEMBER 2000
Alterntor Description The lterntor employs rotor, which is supported in 2 end frmes y ll erings, nd is driven t 2.5 times engine speed. The rotor contins field winding enclosed etween 2 multiple-finger pole pieces. The ends of the field winding re connected to 2 rushes which mke continuous sliding contct with the slip rings. The current (flowing through the field winding) cretes mgnetic field tht cuses the djcent fingers of the pole pieces to ecome lternte north nd south mgnetic poles. A 3-phse sttor is mounted directly over the rotor pole pieces nd etween the 2 end frmes. It consists of 3 windings wound 120 electriclly out-of-phse on the inside of lminted core. The windings re connected together on one end, while the other ends re connected to full-wve rectifier ridge. The rectifier ridge contins 8 diodes which llows current to flow from ground, through the sttor nd to the output terminl, ut not in the opposite direction. When current is supplied to the rotor field winding, nd the rotor is turned, the movement of the mgnetic fields creted induces n lternting current into the sttor windings. The rectifier ridge chnges this lternting current to direct current which ppers t the output terminl. A diode trio is connected to the sttor windings to supply current to the regultor nd the rotor field during opertion. Voltge output of the lterntor is controlled y trnsistorized voltge regultor tht senses the voltge t the ttery nd regultes the field current to mintin lterntor voltge for properly chrging the ttery. Current output of the lterntor does not require regultion, s mximum current output is self-limited y the design of the lterntor. As long s the voltge is regulted within the prescried limits, the lterntor cnnot produce excessive current. A cutout rely in the voltge regultor lso is not required, s the rectifier diodes prevent the ttery from dischrging ck through the sttor. A smll mount of current is supplied y the excittion circuit in the regultor to the rotor field to initilly strt the lterntor chrging. Once the lterntor egins to produce output, field current is supplied solely y the diode trio. The lterntor is equipped with 2 fns which induce ir flow through the lterntor to remove het creted y the rectifier nd sttor. Dignosis of Alterntor System on Engine 1. If prolem is n underchrged ttery, verify condition hs not een cused y excessive ccessory current drw or y ccessories which hve ccidentlly een left on. 2. Check physicl condition nd stte of chrge of ttery. Bttery must e t lest 75% (1.230 specific grvity) of fully chrged to otin vlid results in the following tests. If not, chrge ttery efore testing system. 3. Inspect entire lterntor system wiring for defects. Check ll connections for tightness nd clenliness, prticulrly ttery cle clmps nd ttery terminls. IMPORTANT: RED output led from lterntor must e tight. A drkened RED sleeve indictes led ws loose nd ecoming hot. 4. Check lterntor drive elt for crcks nd frying. Replce if necessry. Check elt tension. Adjust if necessry, s outlined under Drive Belt Replcement nd Adjustment. 90-859769R1 DECEMBER 2000 Pge 2B-13
Alterntor System Circuitry Test Using 0-20 volt DC voltmeter, perform the following tests: Output Circuit 1. Connect POSITIVE (+) voltmeter led to lterntor terminl B (output terminl). Connect NEGATIVE ( ) led to cse ground on lterntor. 2. Shke lterntor wiring hrness. Meter should indicte ttery voltge nd should not vry. If proper reding is not otined, check for loose or dirty connections or dmged wiring. -Terminl B 57813 Pge 2B-14 90-859769R1 DECEMBER 2000
Sensing Circuit 1. Unplug RED nd PURPLE led connector from lterntor. 2. Connect POSITIVE (+) voltmeter led to RED led nd NEGATIVE ( ) voltmeter led to ground. 3. Voltmeter should indicte ttery voltge. If correct voltge is not present, check sensing circuit (RED led) for loose or dirty connections or dmged wiring. 58458 58458 57814 c -Sense Led (RED) -Model Yer 2000 Connector c -Model Yer 2001 Connector 90-859769R1 DECEMBER 2000 Pge 2B-15
Voltge Output 1. Using 0-20 volt DC voltmeter, connect POSITIVE (+) led of voltmeter to TERMINAL B of lterntor nd NEGATIVE ( ) led of voltmeter to engine ground. 2. Strt engine nd llow to wrm up. Increse engine RPM from idle to 2000. Norml voltge output should e 13.5 15.1 volts. If voltge reding is greter thn norml, replce voltge regultor. 3. If voltge reding is less thn norml, fricte tool from piece of stiff wire to the following specifictions: 0.060 in. (1.52 mm) 8 in. (203 mm) -Terminl B 57813 13/16 in. (20.6 mm) 4. Insert ent end of tool through end cover nd ground TERMINAL F. d 51683 c -Terminl F -Tool c -Jumper Wire to Engine Ground (Attch to end of Tool) d-terminl B 57815 5. With TERMINAL F grounded, voltge should rise to within the norml rnge (13.5 15.1). If voltge rises, replce the regultor. 6. If the voltge DOES NOT rise to within the norml rnge with TERMINAL F grounded, perform CURRENT OUTPUT test. Pge 2B-16 90-859769R1 DECEMBER 2000
Current Output 1. With engine shut off, instll mmeter (cple of reding 60+ mperes) in series etween TERMINAL B on lterntor nd POSITIVE (+) terminl of ttery, or if using clmp-on mmeter, plce clmp over output led of lterntor. 2. Strt engine nd llow to wrm up. Advnce RPM to 2000. 3. Insert tool, previously fricted for VOLTAGE OUTPUT, through end cover nd ground TERMINAL F. d c -Terminl F -Tool c -Jumper Wire to Engine Ground d-output Led 57816 4. Norml output is 52 60 mperes @ 2000 RPM @ the lterntor. If output is norml, replce regultor. If output is low, disssemly of the lterntor is necessry to inspect nd test individul components. 90-859769R1 DECEMBER 2000 Pge 2B-17
Repir Removl 1. Remove top cowling. 2. Disconnect ttery cles from ttery. 3. Disconnect wiring hrness from lterntor. 4. Use reker r to relese elt tensioner nd remove lterntor elt. 5. Remove 2 olts securing lterntor. c -Attching Bolts -Hrnesses (hidden) c -Belt Tensioner 57784 Pge 2B-18 90-859769R1 DECEMBER 2000
Instlltion 1. Secure lterntor to engine lock with 2 ttching olts. Torque olts to 40 l-ft (54 Nm). 2. Instll lterntor elt in V-groove of flywheel, lterntor nd compressor pulley. 3. Reconnect electricl hrness to lterntor. c -Bolts [Torque to 40 l-ft (54 Nm)] -Tensioner c -Hrnesses 57784 90-859769R1 DECEMBER 2000 Pge 2B-19
Alterntor Belt Tension Adjustment Correct lterntor elt tension is mintined y elt tensioner ssemly. -Belt Tensioner Assemly 57784 Pge 2B-20 90-859769R1 DECEMBER 2000
Strter System Strter Motor Amperes Drw STARTER MOTOR NO LOAD NORMAL PART NO. AMP. DRAW AMP. DRAW 50-833153-1 30 AMPS 210 AMPS 50-853329-1 60 AMPS 170 AMPS Strter System Components 1. Bttery 2. Strter Solenoid 3. Neutrl Strt Switch 4. Strter Motor 5. Ignition Switch 6. Slve Solenoid (Model Yer 2001) Description The ttery supplies electricity to ctivte the strter motor. When the ignition is turned to the START position, the strter solenoid is energized nd completes the strter circuit etween the ttery nd strter. Model Yer 2001 engines incorporte slve solenoid to ctivte the strter solenoid. 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. 90-859769R1 DECEMBER 2000 Pge 2B-21
Strter Motor (Model Yer 2000)(Centrifugl Bendix) 4 3 5 1 2 14 10 11 6 7 8 9 14 Formul 50 2 Cycle Motor Oil 13 12 15 14 7 Pge 2B-22 90-859769R1 DECEMBER 2000
TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 STARTER MOTOR 2 1 DRIVE CAP 3 2 THRU BOLT 70 8.0 4 1 DRIVE KIT 5 1 PINION 6 1 ARMATURE 7 1 BRUSH/SPRING KIT 8 1 BRUSH HOLDER 9 1 COMMUTATOR CAP 10 2 SCREW Drive Tight 11 1 DECAL, Wrning-High voltge 12 1 LOCKWASHER 13 2 NUT (1/4-20) (SERVICE ITEM) 60 7.0 14 2 LOCKWASHER 15 1 NUT (1/4-20) 60 7.0 16 2 COLLAR 17 2 RUBBER STOP 18 1 SCREW (1/4-20 x 5/8) 80 9.0 19 1 WIRE ASSEMBLY (BLACK) 90-859769R1 DECEMBER 2000 Pge 2B-23
Strter Motor (Model Yer 2001)(Solenoid Driven Bendix) 1 2 3 4 5 6 7 8 12 14 9 13 10 11 23 24 15 16 18 24 25 17 21 19 20 21 22 22 58430 Pge 2B-24 90-859769R1 DECEMBER 2000
Strter Motor (Model Yer 2001)(Solenoid Driven Bendix) TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 2 THRU BOLT 110 12.5 2 2 SCREWS 30 3.4 3 1 END CAP 4 1 BUSHING 5 1 BRUSH PLATE ASSEMBLY 6 1 ARMATURE 7 1 FIELD FRAME 8 1 SOLENOID 9 1 SHIELD 10 1 CUSHION 11 3 PLANETARY GEARS 12 1 PLUG 13 1 DISC 14 1 SHIFT FORK 15 1 GEAR/CLUTCH ASSEMBLY 16 1 BEARING 17 1 HOUSING 18 3 SCREW 40 4.5 19 1 DRIVE GEAR 20 1 SNAP RING 21 2 MOUNTING COLLAR 22 2 STOP 23 2 NUT 55 6.0 24 2 WASHER 25 1 NUT 20 2.3 90-859769R1 DECEMBER 2000 Pge 2B-25
Trouleshooting the Centrifugl Bendix Strter 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. TO ALTERNATOR STARTER BATTERY 2 7 1 20 AMP FUSE 4 6 3 STARTER SOLENOID 5 IGNITION SWITCH NEUTRAL START SWITCH (LOCATED IN CONTROL HOUSING) Strter Circuit Pge 2B-26 90-859769R1 DECEMBER 2000
Strter Circuit Trouleshooting Flow Chrt (Centrifugl Bendix) 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 Step 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 90-859769R1 DECEMBER 2000 Pge 2B-27
TEST 7. Connect voltmeter etween common engine nd Test Point1.. 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 Pge 2B-28 90-859769R1 DECEMBER 2000
Trouleshooting the Solenoid Driven Bendix Strter 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. TO ALTERNATOR BATTERY STARTER STARTER SOLENOID SLAVE SOLENOID 20 AMP FUSE IGNITION SWITCH NEUTRAL START SWITCH (LOCATED IN CONTROL HOUSING) Solenoid Driven Bendix Strter Circuit 58431 90-859769R1 DECEMBER 2000 Pge 2B-29
Strter Circuit Trouleshooting Flow Chrt (Solenoid Driven Bendix) Strter Motor Does Not Turn TEST 1 With ignition key in START position, check for ttery voltge t TEST POINT 1. Voltge indicted nd solenoid clicks No voltge indicted Voltge indicted nd solenoid does not click Voltge indicted t Test Point 9 is 9.5 volts or greter. Go to TEST 2 Check for strter motor ground t Test Point 10 Voltge indicted t Test Point 9 is less thn 9.5 volts. Good ground Bd ground clen cle ends or replce ground cle Defective strter motor Defective strter solenoid Defective strter solenoid SAFETY WARNING: Disconnect BLACK with RED sleeve (strter motor) cle from slve solenoid test point 7 BEFORE mking tests 1 thru 7 to prevent unexpected engine crnking. TEST 2 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 3 No voltge reding: proceed to TEST 4. Test 3. Disconnect BLACK ground wire(s) from Test Point 3.. Connect voltmeter etween common engine ground nd Test Point 3. c. Turn ignition key to Strt position. TEST 4. Reconnect BLACK ground wire.. Connect voltmeter etween common engine ground nd Test Point 4. 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 8. Pge 2B-30 90-859769R1 DECEMBER 2000
No voltge reding: proceed to TEST 5 12 Volt Reding Defective strter solenoid No voltge reding: proceed to TEST 6 TEST 5. Connect voltmeter etween common engine ground nd Test Point 5.. Turn ignition key to Strt position. 12 Volt Reding* Neutrl strt switch is open or YELLOW/RED wire is open etween Test Points 5 nd 4. No voltge reding: proceed to TEST 7 TEST 6 Connect voltmeter etween common engine ground nd Test Point 6 12 Volt Reding* Defective ignition switch. TEST 7 Check for voltge etween common engine ground nd Test Point 7. No voltge reding: Check BLACK cle with RED sleeve etween ttery(+) POSITIVE terminl nd Test Point 8 nd Test Point 7. 12 Volt Reding* Check fuse in RED wire etween Test Points 6 nd 7. Check for open RED wire etween Test Points 6 nd 7. TEST 8. Connect voltmeter etween common engine ground nd Test Point 2.. Turn ignition key to Strt position. No voltge reding: Defective slve solenoid 12 Volt Reding* Should her solenoid click: proceed to TEST 9 TEST 9. Reconnect BLACK cle (with RED sleeve) to slve solenoid Test Point 7.. Connect voltmeter etween common engine ground nd Test Point 7. c. Turn ignition key to Strt position. No voltge reding: Check BLACK cle (with RED sleeve) for poor connection or open circuit. *Bttery Voltge 90-859769R1 DECEMBER 2000 Pge 2B-31
Strter Removl nd Instlltion (2000 Model)(Centrifugl Bendix) Removl CAUTION Disconnect ttery leds from ttery efore removing strter. 1. Disconnect BLACK ground cle from strter. 2. Disconnect BLACK cle (with YELLOW sleeve) from strter. 3. Remove 2 upper olts nd 2 lower olts securing strter nd remove strter. c -BLACK (with YELLOW sleeve) POSITIVE (+) 12-Volt Cle -Upper Mounting Bolts c -Lower Mounting Bolts 57924 Instlltion 1. Secure strter to engine with 4 olts. Use Left top olt to ttch BLACK NEGATIVE ( ) ttery cle. Torque top ttching olts to 23 l. ft. (31 Nm). Torque ottom ttching olts to 21 l. ft. (28.5 Nm). Pge 2B-32 90-859769R1 DECEMBER 2000
2. Secure BLACK cle (with YELLOW sleeve) to POSITIVE (+) terminl on strter. Torque nut to 60 l. in. (7 Nm). d c -Top Bolts [Torque to 23 l. ft. (31 Nm)] -Bottom Bolts [Torque to 21 l. ft. (28.5 Nm)] c -BLACK Cle (with YELLOW sleeve) d-nut [Torque to 60 l. in. (7 Nm)] 57924 Disssemly 1. Remove strter s outlined in Strter Removl nd Instlltion, preceding. 2. Remove 2 through olts from strter. 3. Tp commuttor end cp to loosen nd remove from frme. Do not loose rush springs. -Through Bolts -Commuttor End Cp 11646 90-859769R1 DECEMBER 2000 Pge 2B-33
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.. Remove 2 olts securing NEGATIVE ( ) rushes nd rush holder to end cp. c c -Brush Holder -Positive Brushes c -Negtive Brushes d-positive Terminl d 11656 5. Remove rmture (with drive end cp) from strter frme. 6. Remove locknut nd remove drive ssemly from rmture shft. ef gf hg ed c dc 51711 11658 -Hold Armture Shft with Wrench on Hex Portion of Drive Assemly -Locknut c -Spcer d-spring e -Drive Assemly f -Drive End Cp g-armture Shft h-wsher Pge 2B-34 90-859769R1 DECEMBER 2000
Clening nd Inspection 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. (6.4 mm) 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 ). Testing (For Centrifugl Bendix nd Solenoid Driven Bendix Strters) 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 90-859769R1 DECEMBER 2000 Pge 2B-35
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. 51711 Checking Positive Brushes nd Terminl 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. -POSITIVE (+) Brushes 51711 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. 51711 -NEGATIVE ( ) Brushes -End Cp Pge 2B-36 90-859769R1 DECEMBER 2000
Ressemly 1. If rushes were removed, replce s follows:. Instll POSITIVE rushes (long with POSITIVE terminl) into commuttor end cp. h c ci d e f 52131 -End Cp -POSITIVE Brushes c -POSITIVE Terminl d-insulting Block e -Insulting Wsher f -Hex Nut g-positive (+) Terminl h-long Brush Led i -Push Led into Slot. Instll NEGATIVE rushes (long with rush holder). c g 51713 d d 11656 -POSITIVE (+)Brushes -NEGATIVE ( ) Brushes c -Brush Holder d-bolts (Fsten NEGATIVE Brushes nd Holder) 90-859769R1 DECEMBER 2000 Pge 2B-37
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 11658 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. 6. Luricte ushing (locted in commuttor end cp) with one drop of SAE 10W oil. DO NOT overluricte. 7. To prevent dmge to rushes nd springs when instlling commuttor end cp, it is recommended tht rush retining tool e mde s shown: 1-3/4 (44.5 mm) 2-1/6 (55.1 mm) 9/16 (14.3 mm) 5 (127.0 mm) -Bushing (DO NOT overluricte) Pge 2B-38 90-859769R1 DECEMBER 2000
8. Plce springs nd rushes into rush holder nd hold in plce with rush retiner tool. 9. Instll commuttor end cp onto strter frme. Align mrks on frme with lignment mrks on end cps. Remove rush retiner tool. Instll through olts nd torque to 70 l. in. (8 Nm). 51713 -Brush Retiner Tool -Alignment Mrks 52130 Strter Solenoid Test 1. Disconnect ll wires from solenoid. 2. Connect ohmmeter (R x1 scle) etween terminls 1 nd 2. 3. Connect 12-volt power supply etween 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. DCV ACV DVA 3 1-12-VOLT Supply -VOA Leds 2 4 90-859769R1 DECEMBER 2000 Pge 2B-39
Strter Removl nd Instlltion (2001 Model) (Solenoid Driven Bendix) Removl CAUTION Disconnect ttery leds from ttery efore removing strter. 1. Disconnect ttery cles from ttery. 2. Disconnect wires from strter solenoid terminls. 3. Remove strter trunion mounting olts nd remove strter from engine. -Strter Solenoid -Mounting Bolts 58700 Pge 2B-40 90-859769R1 DECEMBER 2000
Instlltion 1. Secure strter to engine with 4 olts. Use right top olt to ttch BLACK NEGATIVE. Torque top ttching olts to 23 l-ft (31 Nm). Torque ottom ttching olts to 21 l-ft. (28.5 Nm). 2. Secure BLACK cles (with RED sleeves) to POSITIVE (+) terminl on strter solenoid. Torque nut to 55 l-in (6 Nm). c e d -Top Bolts [Torque to 23 l-ft (31 Nm)] -Bottom Bolts [Torque to 21 l-ft (28.5 Nm)] c -BLACK Cles (with RED sleeves) d-nut [Torque to 55 l-in (6 Nm)] e -Strter Solenoid 58700 90-859769R1 DECEMBER 2000 Pge 2B-41
Disssemly (Solenoid Driven Bendix Strter) 1. Remove rush led from solenoid nd through olts from end frme. e c d -Brush Led -Through Bolts c -Strter Solenoid 58434 d-brush Plte Screws e -End Frme 2. Remove rmture nd field frme from drive housing. NOTE: Permnent mgnets inside field frme will e holding rmture in plce. c d -End Frme nd Bering -Screws (2) [Internl Torx Snp On E6 Socket] c -Brush Holder d-armture e -Field Frme e 58430 Pge 2B-42 90-859769R1 DECEMBER 2000
3. Remove shield nd cushion from drive housing. c 58432 -Shield -Cushion c -Drive Housing 4. Remove 3 screws retining strter solenoid. Remove solenoid from drive housing. 5. Remove snp ring nd ger from strter shft. c d e -Drive Housing -Strter Solenoid c -Screws (3) [ Internl Torx Snp On E6 Socket] d-snp Ring e -Pinion Ger 58436 90-859769R1 DECEMBER 2000 Pge 2B-43
6. Remove plnetry ger nd clutch ssemly from drive housing. 7. Remove solenoid rm, metl disc nd plug from drive housing. e c d -Plnetry Ger nd Clutch Assemly -Drive Housing c -Plug d-metl Disc e -Solenoid Arm 58437 8. Inspect drive housing needle ering for roughness. If ering is worn or dmged, ering cn e removed y using n pproprite mndrel to drive/press ering from drive housing. NOTE: If ering hs spun in drive housing ore, drive housing must e replced. -Needle Bering -Drive Housing 58439 Pge 2B-44 90-859769R1 DECEMBER 2000
Clening nd Inspection IMPORTANT: Do not use grese dissolving solvents to clen electricl components, plnetry gers or drive clutch. Solvent will dmge insultion nd wsh the luricnt out of the clutch drive nd gers. Use clen rgs nd compressed ir to clen components. 1. Test over-running clutch ction of drive. Pinion should turn freely in over-running direction nd must not slip in crnking direction. 2. Inspect pinion teeth for wer. 3. Inspect spring for tension nd drive collr for wer. 4. Check tht erings roll freely. If ny roughness is felt, replce ering. 5. Inspect plnetry ger ssemly. Gers must mesh esily nd roll freely with no inding. 90-859769R1 DECEMBER 2000 Pge 2B-45
Ressemly (Solenoid Driven Bendix Strter) 1. Instll solenoid rm with plnetry ger nd clutch ssemly into drive housing. c 58438 -Solenoid Arm -Plnetry Ger nd Clutch Assemly c -Drive Housing 2. Instll metl disc nd plug into drive housing. 58433 -Metl Disc -Plug Pge 2B-46 90-859769R1 DECEMBER 2000
3. Attch solenoid rm to strter solenoid. Instll strter solenoid in drive housing nd secure with 3 screws. Torque screws to 40 l-in (4.5 N.m). 4. Instll drive ger nd secure with snp ring. 5. Reinstll ruer umpers on housing. c e d f -Drive Housing -Strter Solenoid c -Screw (3) [Torque to 40 l-in (4.5 N.m) d-drive Ger e -Snp Ring f -Bumpers 58436 6. Instll cushion nd shield in drive housing. c -Shield -Cushion c -Drive Housing 58432 90-859769R1 DECEMBER 2000 Pge 2B-47
7. Instll field frme over rmture. 8. While holding rushes ck, slide rush plte onto rmture while ligning rush led grommet with slot in field frme. 9. Secure end plte to rush ssemly with 2 screws. Torque screws to 30 l-in (3.4 Nm) NOTE: Prior to instlling field frme ssemly into drive housing, lign slot in field frme with plug in drive housing. g d c e f 58435 -Armture -Field Frme Grommet Slot c -Brush Plte d-brush Led Grommet e -End Plte f -Screws [Torque to 30 l-in (3.4 Nm)] g-field Frme Plug Slot Pge 2B-48 90-859769R1 DECEMBER 2000
10. Instll field frme nd end frme in drive housing. 11. Instll through olts nd rush led. Torque through olts to 110 l-in (12.5 Nm). Torque rush nut to 55 l-in (6 Nm). d c e f -End Frme -Field Frme c -Drive Housing d-through Bolts [Torque to 110 l-in (12.5 Nm)] e -Brush Led f -Brush Nut [Torque to 55 l-in (6 Nm)] 58434 90-859769R1 DECEMBER 2000 Pge 2B-49
Commnder 2000 Key Switch Test 1. Disconnect remote control wiring hrness nd instrument pnel connector. 2. Set ohmmeter on R x 1 scle for the following tests. 3. If meter redings re other thn specified in the following tests, verify tht switch nd not wiring is fulty. If wiring checks ok, replce switch. IMPORTANT: Key switch must e positioned to RUN or START nd key pushed in to ctute choke for this test. KEY POSITION CONTINUITY SHOULD BE INDICATED AT THE FOLLOWING POINTS: BLK BLK/YEL RED YEL/RED PUR YEL/BLK OFF RUN START CHOKE* Pge 2B-50 90-859769R1 DECEMBER 2000