Operating instructions
ENG
IN
E ELECTRICAL
Electric Starter System
Testing (Static)
Starter Motor Static Testing
I
GN
IT
JON
SW
ITCH
IGNIT I
ON
WIRE
COLORS
G
TERMINAL
-
BRO
WN - GR
OUND
B
TERMINAL
-
RED
-
BA
T
TERY
M T
ERMINAL
-
BLACK
- I
GNIT
IO
N
S
TERMINAL
-
RE
D/
WHITE
-
STAR
T
ER
OFF
RUN
START
::
~
:
R B
R/W
S
I
GNIT
I
ON
SW
ITCH
COLOR
CODE
R 0 R
ED
BRN
0
BROWN
BLK
0 BL
ACK
Y 0
YELLO
W
R/W
0
RE
D W
ITH
WHITE
T
RACER
ALTERNA
TO
R
OUTPUT
I
I
I
~:
RECT
IF
IER
:
-=-
BA
TTER
Y
IG
NIT I
ON
SW
ITC
H
SYS
TE
M
BR
N-G
R
OUN
D
R
'--
- - - R' W
--
- -
-.
C I R
CU
IT
BREAKE
R
(8
AM
P )
/
/
, -
",,"
-:::::
R (C)
/
START
ER
R
EL
AY
-
----
---
- (8)
CH
ASS IS
GNO
1
,--
----
- -
---
(E) __
____
__ _ 1 _
I
EN
GI
NE
GND
-=
I -
1 - I
~
_P
:!~~
E
_
G
~
Q
_____
__
J
A-E See page 4.31
6.
Remove starter motor and disassemble. Mark end covers and housing for proper reassembly.
7.
Remove pinion retaining snap ring, spring and pinion gear.
8. Remove brush end bushing dust cover.
9. Remove housing through bolt
s.
10. Slide brush end frame off end of starter.
NOTE:
The electrical input post must stay with the field co
il
housing.
1
1.
S
li
de positive brush springs to the s
id
e,
pull brushes out of their guides and remove brush plate.
12. Clean and
in
spect starter components.
NOTE:
Some cleaning solvents may damage the
in
s
ul
ation
in
the
starter. Care should be exercised when selecting an appropriate solvent. The brushes must
sl
ide freely
in
their holders. If the commutator needs clean
in
g, use only
an
electrical contact cleaner and/or a non-metallic
grit sandpaper. Replace brush assembly when worn to 5/16" (.8 cm) or less.
Starter Housing and Field Coil Inspection
1. Using a digital multitester, measure resistance between starter input terminal and insulated brushes. The
reading
should be .3 ohms or less.
2. Measure resistance between insulated brushes and
fi
eld coil housing. The reading should be infinite.
3.
Inspect insulated brush wire and
fi
e
ld
coil
in
sulation for damage. Repair or replace components as required.
Armature Testing
1.
Using a digital multitester, measure
re
sistance between each of the segments of the commutator. The
reading should indicate .3 ohms or less.
2. Measure resistance between commutator and armature shaft. Reading sho
ul
d be infinity.
3. Place armature in a growler. With the growler on, position a hacksaw blade lengthwise 1/8" (.03 cm) above
armature coil laminate
s.
Rotate a
rm
ature 360
°.
If hacksaw blade is drawn to the armature on any pole, the
armature is shorted and must be replaced.
8/94
4.32