ELECTRICAL SYSTEMS 4 A 72079 STARTING SYSTEM
Tle of Contents Pge Strters (PG260 And Delo-Remy)......... 4A-1 Speifitions......................... 4A-1 Torque Speifitions.................. 4A-2 Lurints, Selers nd Adhesives....... 4A-2 Identifition.......................... 4A-2 Bttery Cle Reommendtions........ 4A-2 Strting System Components For PG260 (Typil Digrm)........................ 4A-3 Strting System Components for Delo-Remy Diret Drive Strter (Typil Digrm)...... 4A-4 PG 260 Strter Motor (Exploded View)...................... 4A-5 Delo-Remy Strter Motor (Exploded View)...................... 4A-6 Replement Prts Wrning............... 4A-7 Mintenne.......................... 4A-7 Testing............................... 4A-7 Storge.............................. 4A-8 Positive Current Flow..................... 4A-8 Desription.............................. 4A-8 Solenoid Swith.......................... 4A-8 Periodi Inspetion....................... 4A-8 Strter Motor Repir...................... 4A-9 Removl............................. 4A-9 Disssemly.......................... 4A-9 Clening nd Inspetion............... 4A-11 Armture Tests....................... 4A-11 Armture Bering (Commuttor End).... 4A-11 Ger Bering........................ 4A-12 Shft Assemly Bering............... 4A-12 Drive End Housing Bering............ 4A-12 Brushes nd Brush Holder............. 4A-13 Ressemly......................... 4A-14 Clernes.......................... 4A-16 Instlltion........................... 4A-17 Stndrd Strter Slve Solenoid.......... 4A-17 Testing/Replement.................. 4A-17 Delo PG 260........................... 4A-18 Identifition......................... 4A-18 Replement Prts Wrning.............. 4A-18 Mintenne......................... 4A-18 Solenoid Swith......................... 4A-18 Periodi Inspetion...................... 4A-18 Strter Motor Repir..................... 4A-18 Removl............................ 4A-18 Disssemly......................... 4A-19 Clening nd Inspetion............... 4A-21 Armture Tests....................... 4A-21 Brushes nd Brush Holder............. 4A-22 Ressemly......................... 4A-22 Clernes.......................... 4A-25 Instlltion........................... 4A-26 4A-0 - STARTERS 90-823224--1 996
Strters (PG260 And Delo-Remy) Speifitions DELCO-REMY DIRECT DRIVE STARTER Delo Identifition Numer Engine Rottion Volts Min. Amps No Lod Test Mx Amps Min RPM Mx RPM 1998317 10455602 LH 10.6 70 120 5,400 10,800 Pinion Clerne.010-.140 (.025-3.5 mm) Commuttor End Frme Gp.025 (0.6 mm) Mx Brush Spring Tension Oz.(Grms) 56-105 (1588-2976) PG 260 STARTER Delo No Lod Test Brush Min Mx Min Mx Volts Amps Amps RPMS RPMS Identifition Numer 9000820 9000821 9000819 10.6 60 95 2750 2750 Pinion Clerne.010-.160 (0.25-4.00) Bering Depth.011-.014 (0.28-0.38) Bering Depth.099-.017 (.025-.045) Spring Tension Oz.(Grms) 83-104 (2353-2948) 90-823226--1 996 STARTERS - 4A-1
Torque Speifitions Desription L. In. L. Ft. N m Strter Mounting Bolts Diret Drive 50 68 Strter Mounting Bolts PG 260 30 41 Commuttor End Frme (End Cp) 110 12 Bttery Cles Seurely Lurints, Selers nd Adhesives Desription Prt Numer Quiksilver Liquid Neoprene 92-25711-2 Quiksilver 2-C-4 Mrine Lurint With Teflon 92-825407A3 Quiksilver Perfet Sel 92-34227-1 Identifition Bttery Cle Reommendtions Cle Length Feet (Meters) Up to 3.5(1.1) Cle Guge (mm) 4 (25mm2) 3.5-6 (1.1-1.8) 2 (35mm2) 6-7.5(1.8-2.3) 1 (50mm2) 7.5-9.5(2.3-2.9) 0 (50mm2) 8.5-12(2.9-3.7) 00 (70mm2) 12-15(3.7-4.6) 000 (95mm2) 15-19(4.6-5.8) 0000 (120mm2) Permnent Mgnet Ger Redution (PG260) Strter Motor 72789 Delo-Remy Diret Drive Strter Motor 4A-2 - STARTERS 90-823224--1 996
Strting System Components For PG260 (Typil Digrm) B S I g f e h d 72929 - Ignition Swith - 20 Ampere Fuse - Neutrl Sfety Swith d - Ground Stud e - Strter Motor f - Ciruit Breker g - Strter Slve Solenoid h - Wire Juntion 90-823226--1 996 STARTERS - 4A-3
Strting System Components for Delo-Remy Diret Drive Strter (Typil Digrm) g B S I f e h d 7293 - Ignition Swith - 20 Ampere Fuse - Neutrl Sfety Swith d - Ground Stud e - Strter Motor f - Ciruit Breker g - Strter Slve Solenoid h - Wire Juntion 4A-4 - STARTERS 90-823224--1 996
PG 260 Strter Motor (Exploded View) 20 1 2 6 3 7 8 4 16 9 5 17 18 11 10 21 12 13 14 15 19 74270 1 - Srew 2 - End Cp 3 - Brushes with Holder 4 - Armture 5 - Field Frme (with Permnent Mgnets) 6 - Wsher 7 - Shield 8 - Plnetry Gers 9 - Shft 10- Ger 11- Drive 90-823226--1 996 STARTERS - 4A-5
Delo-Remy Strter Motor (Exploded View) 27 1 9 8 28 2 7 29 3 10 31 26 6 5 4 25 11 13 30 24 12 32 33 19 14 15 21 34 20 23 22 17 16 18 72806 1 - Drive End Housing 2 - Drive End Housing Bushing 3 - Thrust Collr 4 - Retining Ring - Pinion Stop Collr 5 - Pinion Stop Collr 6 - Cluth Drive Assemly 7 - Bering Plte 8 - Bering Plte Bushing 9 - Bering Plte Wsher 10- Bering Plte Srew 11- Armture 12- Pole Shoe - Field Coil 13- Pole Shoe to Field Coil Srew 14- Field Coil Grommet - Field Frme 15- Field Coil Assemly 16- Lether Wsher - Commuttor End Frme 17- Lower Commuttor End Frme 18- Thru Bolt 19- Insulted Holder - Field Frme Brush 4A-6 - STARTERS 90-823224--1 996
Replement Prts Wrning! WARNING Eletril, ignition nd fuel system omponents on your MerCruiser re designed nd mnuftured to omply with U.S. Cost Gurd Rules nd Regultions to minimize risks of fire nd explosion. Use of replement eletril, ignition or fuel system omponents, whih do not omply with these rules nd regultions, ould result in fire or explosion hzrd nd should e voided. Mintenne! WARNING Do not use jumper les nd ooster ttery to strt engine. Do not rehrge wek ttery in the ot. Remove ttery nd rehrge in ventilted re wy from fuel vpors, sprks or flmes.! WARNING Btteries ontin id whih n use severe urns. Avoid ontt with skin, eyes nd lothing. Btteries lso produe hydrogen nd oxygen gses when eing hrged. This explosive gs espes fill/vent ell ps nd my form n explosive tmosphere round the ttery for severl hours fter it hs een hrged; sprks or flmes n ignite the gs nd use n explosion whih my shtter the ttery nd ould use lindness or other serious injury. Sfety glsses nd ruer gloves re reommended when hndling tteries or filling with eletrolyte. Hydrogen gses tht espe from the ttery during hrging re explosive. When hrging tteries, e sure ttery omprtment, or re where ttery is loted, is well vented. Bttery eletrolyte is orrosive id nd should e hndled with re. If eletrolyte is spilled or splshed on ny prt of the ody, immeditely flush the exposed re with lierl mounts of wter nd otin medil id s soon s possile.! CAUTION To prevent dmge to the eletril system e sure to dhere to the following: When instlling ttery, e sure to onnet the POSITIVE (+) ttery le to POSITIVE (+) ttery terminl first nd then the NEGATIVE ( ) ttery le to NEGATIVE ( ) ttery terminl. Never disonnet the ttery les while the engine is running. If hrger or ooster is to e used, e sure to onnet it in prllel with existing ttery (positive to positive nd negtive to negtive). When pplying ooster hrge to ttery, disonnet oth les from ttery (to prevent dmge to voltge regultor). Chek ttery ondition periodilly. Mke sure tht ttery leds re kept len nd tight. Testing! CAUTION Test ttery in well ventilted re s gses given off y ttery re hzrdous. Ple ttery under hevy lod (s during engine rnking or with vrile resistor tester) nd test ell voltge while under lod. Certin onditions must e met efore testing. Bttery must e 60 to 100 F (16 to 38 C). Eletrolyte level must e orret in ll ells. Bttery must e t lest hlf hrged. No ovious defets. 1. Chek voltge per mnufturer s speifitions. 2. If redings re low, rehrge nd retest. 3. If redings remin low, ttery should e repled. 90-823226--1 996 STARTERS - 4A-7
Storge 1. Remove ttery nd len exterior. 2. Chek fluid level nd fill if low. 3. Cover terminls nd olts with light ot of grese. 4. Set ttery on wood or in rton; store in ool, dry ple. 5. Chek every 20 dys for fluid level nd slow hrge. IMPORTANT: A dishrged ttery n e dmged y freezing. Positive Current Flow This is generl desription of the positive urrent flow, from the ttery nd through the system until the strter motor rnks. Bttery to the solenoid swith (on strter) (RED ttery le). Solenoid swith to iruit reker (RED). Ciruit reker to wire juntion (RED-PUR). Wire juntion to wiring hrness plug (RED-PUR) terminl 6. Wiring hrness plug to 20 mp fuse (RED-PUR). 20 mp fuse to ignition swith terminl I (RED-PUR). At this point ignition swith is turned to START. Ignition swith terminl I to terminl C. Ignition swith terminl C to neutrl strt swith (YEL-RED). NEUTRAL START SWITCH MUST BE AT NEUTRAL POSITION. Neutrl strt swith to wiring hrness plug terminl 7 (YEL-RED). Wiring hrness plug to strter solenoid (smll terminl) (YEL-RED). Also ensure tht lk (smll terminl) wire is grounded. Desription The Delo PG 200 strter motor fetures smll permnent mgnets mounted inside the field frme. These mgnets tke the ple of urrent-rrying field oils mounted on iron pole piees. Internl ger redution, pproximtely 4 to 1, through plnetry gers results in rmture speeds in the 7000 RPM rnge. The rmture nd drive shft re mounted on roller or ll erings in ple of ushings. The solenoid swith, plunger, return spring, nd shift lever re permnently mounted in the drive housing.! CAUTION The strter motor is designed to operte under gret overlod nd produe high horsepower for its size. It n do this only for short time, sine onsiderle het umultes nd n use serious dmge. For this reson, the rnking motor must never e used for more thn 30 seonds t ny one time. Crnking should not e repeted without puse of t lest 2 minutes to permit the het to espe. Solenoid Swith The solenoid swith, long with plunger, return spring, nd shift lever, re ompletely seled nd permnently mount-ed in the drive housing. If solenoid is defetive, entire drive housing must e repled. Periodi Inspetion Crnking motor nd solenoid re ompletely enlosed in the drive housing to prevent entrne of moisture nd dirt. However, periodi inspetion is required s follows: 1. Inspet terminls for orrosion nd loose onnetions. 2. Inspet wiring for fryed nd worn insultion. 3. Chek strter mounting olts for tightness. Strter solenoid is now losed, ompleting iruit etween lrge terminl (RED-PUR) nd other lrge terminl (YEL-RED), using strter motor to rnk. 4A-8 - STARTERS 90-823224--1 996
Strter Motor Repir Removl! WARNING 2. Remove thru olts nd seprte field frme with rmture from drive housing. Disonnet ttery les t ttery efore removing strter. 1. Disonnet ttery les from ttery. 2. Disonnet wires from solenoid terminls. IMPORTANT: Some strter motors my use speil mounting shim for gining flywheel lerne. Do not lose this shim; it will e needed when remounting strter on engine lok. 3. Remove strter mounting olts. 4. Pull strter ssemly wy from flywheel nd remove from engine. 72061 - Field Frme/Armture - Drive Housing - Thru Bolts 3. Pull rmture out of field frme. NOTE: Permnent mgnets inside field frme will e holding rmture in ple. Disssemly 1. Remove rush led from solenoid nd srews from end frme. 72062 72060 - Armture - Field Frme 4. Pull end frme off ering. - Brush Led - Srews 72063 - End Frme - Bering 90-823226--1 996 STARTERS - 4A-9
5. Remove shield. 7. Remove thrust ollr, retining ring nd ollr. Remove drive. d 72067 - Shield 72065 - Thrust Collr - Retining Ring - Collr d - Drive 6. Use srewdriver, s shown, to disengge shift lever from drive. 8. Remove ger from shft ssemly. 72066 - Shift Lever 72064 - Ger - Shft Assemly 4A-10 - STARTERS 90-823224--1 996
Clening nd Inspetion IMPORTANT: Do not use grese dissolving solvents to len eletril omponents, plnetry gers, or drive. Solvent will dmge insultion nd wsh the lurint out of the drive nd gers. Use len rgs nd ompressed ir to len omponents. 1. Test over-running luth tion of drive. Pinion should turn freely in over-running diretion nd must not slip in rnking diretion. Chek pinion teeth. Chek spring for tension nd drive ollr for wer. Reple if neessry. 2. Chek tht rush holders re not dmged or ent nd hold rushes ginst ommuttor. Chek rushes for wer; refer to Brushes nd Brush Holder. 3. Inspet rmture ommuttor. If dly grooved or out-of-round, turn down nd underut ommuttor. 4. Inspet ll roller ering surfes for wer. Chek tht erings roll freely. If ny roughness is felt, reple erings. 5. Inspet plnetry ger ssemly. Gers must mesh esily nd roll freely with no inding. Armture Tests TEST FOR SHORTS Chek rmture for shorts y pling on growler nd holding hk sw lde over rmture ore while rotting rmture. If sw lde virtes, rmture is shorted. After lening etween ommuttor rs, rehek. If sw lde still virtes, reple rmture. TEST FOR GROUND 1. With ontinuity meter, ple one led on rmture ore or shft nd other led on ommuttor. 2. If meter hnd moves, rmture is grounded nd must e repled. - Commuttor - Armture Core - Shft d - Growler 01441 Armture Bering (Commuttor End) REMOVAL Use universl puller plte, s shown, to remove ering. d - Hksw Blde - Armture Core - Growler 01440 - Universl Puller Plte - Bering 72068 90-823226--1 996 STARTERS - 4A-11
INSTALLATION IMPORTANT: Brush holder must e instlled on rmture efore instlling rmture ering. Using the orret size driver, press on inner ering re until it ontts shoulder of rmture shft. Shft Assemly Bering IMPORTANT: Roller ering is not replele. If ering is defetive, reple entire shft ssemly. Apply Quiksilver 2-4-C Mrine Lurint with Teflon to ering efore strter ressemly. Ger Bering REMOVAL Using the orret size driver, press ering out of ger. INSTALLATION 1. Using the orret size driver, press ering into ger, from diretion shown, to depth speified. 72070 - Roller Bering Drive End Housing Bering INSTALLATION DIRECTION REMOVAL Using the orret size driver, press ering out of housing. 72625 - Depth -.011 -.014 in (0.28-0.38 mm) 2. Lurite ering nd ger teeth with smll mount of Quiksilver 2-4-C Mrine Lurint with Teflon. 72626 - Drive End Housing - Bering 4A-12 - STARTERS 90-823224--1 996
INSTALLATION 1. Using the orret size driver, press ering into housing, from diretion shown, to depth speified. REMOVAL 1. Remove rmture ering s previously desried. 2. Remove rush holder. INSTALLATION 1. Push eh rush up into its guide to llow spring to hold it in ple, s shown. INSTALLATION DIRECTION 72626 - Depth -.009-.017 in. (0.25-0.45 mm) 2. Lurite ering with smll mount of Quiksilver 2-4-C Mrine Lurint. Brushes nd Brush Holder INSPECTION Reple rushes nd holder when rush leds re touhing guide. Mke sure rushes move freely in guides. - Brush - Guide - Brush Spring 72072 2. Ple rush holder on rmture nd push rushes down ginst ommuttor, s shown. 72069 - Brush Leds - Guide 72069 - Brush Holder - Commuttor - Brush 3. Instll rmture ering s previously desried. 90-823226--1 996 STARTERS - 4A-13
Ressemly 1. Instll end frme on rush holder. Align holes of end frme with holes of rush holder. Tighten srews seurely. 3. Cot roller erings nd ger with smll mount of Quiksilver 2-4-C Mrine Lurint. 72627 72063 - Roller Bering - Roller Bering - Ger 4. Assemle ger nd shft together, s shown. - Holes of End Frme - Holes of Brush Holder 2. Insert rmture into field frme. Align rush holder led with noth in field frme. NOTE: Permnent mgnets in field frme will pull rmture in ple. - Ger Assemly - Shft Assemly 72070 72062 - Brush Holder Led - Noth 4A-14 - STARTERS 90-823224--1 996
5. Assemle drive on shft ssemly s follows:. Lurite drive end of shft ssemly with SAE 10W oil.. Slide drive ssemly onto shft with pinion outwrd.. Slide retiner onto shft with upped surfe fing end of shft (wy from pinion). d. Position snp ring on upper end of shft nd hold in ple with lok of wood. Strike wood lok with hmmer, thus foring snp ring over end of shft. Slide snp ring down into groove. f. Position retiner nd thrust ollr next to snp ring. Then, using two pliers, grip retiner nd thrust ollr nd squeeze until snp ring is fored into retiner. 72074 - Retiner - Thrust Collr - Snp Ring 6. Apply thin oting of Quiksilver 2-4-C Mrine Lurint with Teflon to roller ering in drive housing. 7. Insert shft nd drive ssemly into drive housing. Pins of drive must e snpped into holes of shift lever. Thrust ollr must e in ple efore shft is inserted in housing roller ering. 72073 - Snp Ring - Groove - Retiner e. Assemle thrust ollr on shft with shoulder next to snp ring. 72628 72075 - Pins of Drive - Holes of Shift Lever - Thrust Collr 90-823226--1 996 STARTERS - 4A-15
8. Instll shield. Align rush led nd solenoid terminl when inserting rmture into plnetry gers. Clernes PINION CLEARANCE Pinion lerne must e heked fter ressemly of strter motor. 1. Disonnet rush led from solenoid motor terminl M nd insulte it refully. 72061 - Shield - Brush Led - Solenoid Terminl 9. Instll thru olts nd rush led. Tighten fsteners seurely. IMPORTANT: Do not overtighten thru olts. Overtightening will end end frme. - Brush Led 72060 2. Connet 12 volt ttery positive (+) led to solenoid swith terminl nd negtive ( ) led to solenoid frme. 3. Momentrily touh jumper led from solenoid motor terminl M to strter motor frme. This shifts pinion into rnking position where it will remin until ttery is disonneted. 72060 - Thru Bolts - Brush Led 72629 4. Push pinion k towrd ommuttor end to eliminte slk. 4A-16 - STARTERS 90-823224--1 996
5. Mesure distne etween pinion nd pinion retiner. 6. If lerne is not within limits of.010-.160 in. (0.25-4.00 mm), it my indite exessive wer of solenoid linkge, shift lever yoke uttons, or improper ssemly of shift lever mehnism. Reple worn or defetive prts, sine no provision is mde for djusting pinion lerne. Stndrd Strter Slve Solenoid Testing/Replement 1. Using ontinuity meter, onnet test leds s shown, nd onnet 12 volt ttery with jumper leds s shown. 72077 - Pinion - Retiner - Feeler Guge 72630 Instlltion IMPORTANT: Instll speil mounting shim (if equipped) etween strter motor nd engine lok. 1. Ple strter motor in position nd instll mounting olts. Torque olts to 30 l. ft. (41 N m). 2. Connet YELLOW/RED wire to terminl S of solenoid. Connet ORANGE wire, RED wire, nd ttery le to lrge terminl of solenoid. Tighten fsteners seurely. Cot terminls with Quiksilver Liquid Neoprene. Instll ttery le oot, if so equipped. 3. Connet ttery les to ttery in the following order. Connet positive (+) le to positive (+) ttery terminl nd tighten le lmp. Then onnet negtive ( ) le to negtive ( ) terminl nd tighten lmp. 2. If no meter movement is present, reple solenoid. 90-823226--1 996 STARTERS - 4A-17
Delo PG 260 Identifition The strter identifition numer is loted s shown. Permnent Mgnet Ger Redution (PG260) Strter Motor - Strter Identifition Numer Replement Prts Wrning! WARNING Eletril, ignition nd fuel system omponents on your MerCruiser re designed nd mnuftured to omply with U.S. Cost Gurd Rules nd Regultions to minimize risks of fire nd explosion. Use of replement eletril, ignition or fuel system omponents, whih do not omply with these rules nd regultions, ould result in fire or explosion hzrd nd should e voided. Mintenne! WARNING DO NOT use jumper les nd ooster ttery to strt engine. DO NOT rehrge wek ttery in the ot. Remove ttery nd rehrge in well ventilted re wy from fuel vpors, sprks or flmes.! WARNING Btteries ontin id whih n use severe urns. Avoid ontt with skin, eyes nd lothing. Btteries lso produe hydrogen nd oxygen gses when eing hrged. This explosive gs espes fill/vent ps nd my form n explosive tmosphere round the ttery for severl hours fter it hs een hrged; sprks or flmes n ignite the gs nd use n explosion whih my shtter the ttery nd ould use lindness or other serious injury. Sfety glsses nd ruer gloves re reommended when hndling tteries or filling eletrolyte. Hydrogen gses tht espe from the ttery during hrging re explosive. When hrging tteries, e sure ttery omprtment, or re where tteries re loted, is well vented. Bttery eletrolyte is orrosive id nd should e hndled with re. If eletrolyte is spilled or splshed on ny prt of the ody, immeditely flush the exposed re with lierl mounts of wter nd otin medil id s soon s possile. Solenoid Swith The solenoid swith n e removed nd repled if defetive. Periodi Inspetion Crnking motor nd solenoid re ompletely enlosed in the drive housing to prevent entrne of moisture nd dirt. However, periodi inspetion is required s follows: 1. Inspet terminls for orrosion nd loose onnetions. 2. Inspet wiring for fryed nd worn insultion. 3. Chek strter mounting olts for tightness. Strter Motor Repir Removl! WARNING Disonnet ttery les t ttery efore removing strter. 4A-18 - STARTERS 90-823224--1 996
1. Disonnet ttery les from ttery. 2. Disonnet wires from solenoid terminls. IMPORTANT: Some strter motors my use speil mounting shim for gining flywheel lerne. Do not lose this shim; it will e needed when remounting strter on engine lok. 3. Remove strter mounting olts. 4. Pull strter ssemly wy from flywheel nd remove from engine. Disssemly 1. Remove rush led from solenoid nd srews from end frme. 74037 - Brush Holder - End Cp - Srews (2) 4. Remove rmture nd field frme from drive housing. 5. Pull rmture out of field frme. NOTE: Permnent mgnets inside field frme will e holding rmture in ple. - Brush Led - Srews 74041 2. Remove thru olts nd seprte end frme from field frme nd end p. - Armture - Field Frme 6. Remove shield nd wsher. 74086 - End Cp - Thru Bolt - Drive Housing 3. Remove rush holder from end p. 74040 - Shield - Wsher 74038 90-823226--1 996 STARTERS - 4A-19
7. Remove the three srews retining the solenoid. Remove solenoid from drive housing. 9. Remove solenoid rm nd ruer grommet from the drive housing. 74105 74048 - Drive Housing - Solenoid - Srews (3) 74036 8. Remove drive nd ssoited prts from drive housing. 74018 - Ruer Grommet - Solenoid - Drive Housing - Drive Housing - Drive 74035 10. Remove thrust ollr, retining ring nd ollr from plnetry shft. d 74016 - Thrust Collr - Retining Ring - Collr d - Drive 4A-20 - STARTERS 90-823224--1 996
11. Remove drive nd ger from plnetry shft. Armture Tests TEST FOR SHORTS Chek rmture for shorts y pling on growler nd holding hk sw lde over rmture ore while rotting rmture. If sw lde virtes, rmture is shorted. After lening etween ommuttor rs, rehek. If sw lde still virtes, reple rmture. 74087 01440 e - Ger f - Shft Assemly g - Drive Clening nd Inspetion IMPORTANT: Do not use grese dissolving solvents to len eletril omponents, plnetry gers, or drive. Solvent will dmge insultion nd wsh the lurint out of the drive nd gers. Use len rgs nd ompressed ir to len omponents. 1. Test over-running luth tion of drive. Pinion should turn freely in over-running diretion nd must not slip in rnking diretion. Chek pinion teeth. Chek spring for tension nd drive ollr for wer. Reple if neessry. 2. Chek tht rush holders re not dmged or ent nd hold rushes ginst ommuttor. Chek rushes for wer; refer to Brushes nd Brush Holder. 3. Inspet rmture ommuttor. If dly grooved or out-of-round, turn down nd underut ommuttor. 4. Inspet ll roller ering surfes for wer. Chek tht erings roll freely. If ny roughness is felt, reple erings. 5. Inspet plnetry ger ssemly. Gers must mesh esily nd roll freely with no inding. - Hksw Blde - Armture Core - Growler TEST FOR GROUND 1. With ontinuity meter, ple one led on rmture ore or shft nd other led on ommuttor. 2. If meter hnd moves, rmture is grounded nd must e repled. - Commuttor - Armture Core - Shft d - Growler d 01441 90-823226--1 996 STARTERS - 4A-21
Brushes nd Brush Holder INSPECTION Reple rushes nd holder when rush leds re touhing guide. Mke sure rushes move freely in guides. 2. Ple rush holder on rmture nd remove piees of wires from rush holder. 72069 - Brush Holder - Brush - Brush Leds - Guide INSTALLATION 72069 Ressemly 1. Instll end frme on rush holder. Align holes of end frme with holes of rush holder. Tighten srews seurely. 1. Push eh rush up into its guide, use 3 inh piee of ot hnger wire or similr stiff wire to retin the spring while instlling rmture, s shown. d d 72069 - Brush - Guide - Brush Spring d - 3-Inh Piee of Cot Hnger or Similr Still Wire - Srew (2) - End Cp - Brush Holder d - Armture 4A-22 - STARTERS 90-823224--1 996
2. Instll ger nd drive over plnetry shft. e. Position snp ring on upper end of shft nd hold in ple with lok of wood. Strike wood lok with hmmer, thus foring snp ring over end of shft. Slide snp ring down into groove. 72073 - Plnetry Shft - Ger - Drive 74087 - Snp Ring - Groove - Retiner f. Assemle thrust ollr on shft with shoulder next to snp ring. g. Position retiner nd thrust ollr next to snp ring. Then, using two pliers, grip retiner nd thrust ollr nd squeeze until snp ring is fored into retiner. 3. Assemle drive on shft ssemly s follows:. Lurite drive end of shft ssemly with SAE 10W oil.. Ple ger over shft.. Slide drive ssemly onto shft with pinion fing outwrd. d. Slide retiner onto shft with upped surfe fing end of shft (wy from pinion). 72074 - Retiner - Thrust Collr - Snp Ring 90-823226--1 996 STARTERS - 4A-23
4. Instll the plnetry gers on plnetry shft. 5. Instll solenoid rm nd ruer grommet in the drive housing. 7. Ple solenoid in drive housing nd tighten srews. 74036 - Drive Housing - Solenoid - Srews (3) 8. Instll shield nd wsher in drive housing. 74135 - Ruer Grommet - Solenoid - Drive Housing 6. Instll drive nd ssoited prts in drive housing. 74038 - Shield - Wsher 74035 9. Instll field frme nd rmture in drive housing. Align slot in end p nd field frme for proper positioning of ruer grommet. Rotte nd lign gers nd ruer gsket with slot in rmture - Drive Housing - Drive 4A-24 - STARTERS 90-823224--1 996
10. Instll field frme nd end p in drive housing lign slots in field frme with reess in drive housing. 3. Momentrily touh jumper led from ttery terminl to swith terminl. This shifts pinion into rnking position where it will remin until ttery is disonneted. - Drive Housing - End Cp nd Field Frme 11. Instll thru olts nd rush led. Tighten fsteners seurely. Clernes PINION CLEARANCE Pinion lerne must e heked fter ressemly of strter motor. 1. Disonnet rush led from solenoid motor nd insulte it refully. 72629 4. Push pinion k towrd ommuttor end to eliminte slk. 5. Mesure distne etween pinion nd pinion retiner. 6. If lerne is not within limits of.010-.160 in. (0.25-4.00 mm), it my indite exessive wer of solenoid linkge, shift lever yoke, or improper ssemly of shift lever mehnism. Reple worn or defetive prts, sine no provision is mde for djusting pinion lerne. - Brush Led 74041 2. Connet 12 volt ttery positive (+) led to ttery terminl nd negtive ( ) led to frme. 72077 - Pinion - Retiner - Feeler Guges 90-823226--1 996 STARTERS - 4A-25
Instlltion IMPORTANT: Instll speil mounting shim (if equipped) etween strter motor nd engine lok. 1. Ple strter motor in position nd instll mounting olts. Torque olts to 30 l. ft. (41 N m). 2. Connet YELLOW/RED wire to terminl S of solenoid. Connet ORANGE wire, RED wire, nd ttery le to lrge terminl of solenoid. Tighten fsteners seurely. Cot terminls with Quiksilver Liquid Neoprene. Instll ttery le oot, if so equipped. 3. Connet ttery les to ttery in the following order. Connet positive (+) le to positive (+) ttery terminl nd tighten le lmp. Then onnet negtive ( ) le to negtive ( ) terminl nd tighten lmp. 4A-26 - STARTERS 90-823224--1 996