Owners manual

INSTALLATION:
[1]
MOUNT STARTER . Make sure the mounting surface of the engine block is smooth, flat and free of paint buildup.
Torque starter mounting bolts to engine manufacturer’s specifications, typically 32 ft. lbs.
[2]
CHECK PINION CLEARANCE . There should be 1/16” minimum from the back side of ring gear to the front edge
of the teeth on the starter pinion. Check in at least three locations on the ring gear (see Figure 1). If not in spec,
verify that the ring gear is properly mounted.
[3] CHECK PINION ENGAGEMENT . Pull pinion out to engage ring gear. This can be done by:
– Using a tool to pry the pinion out of the starter or connect 12 VDC to the “Switch” terminal ONLY (DO NOT connect battery cable
to “BAT” terminal on the starter solenoid). This engages the solenoid but does not spin the starter. CAUTION: Do not leave the
solenoid engaged like this for more than 30 seconds at a time as the solenoid will overheat.
[PLEASE NOTE: After releasing the solenoid, the pinion may STAY ENGAGED in the ring gear until the engine is started.
This is normal for gear r
eduction starters and does NOT require shimming to correct. ]
– Insert a wire gauge to check for proper clearance between the ring gear and starter
pinion (see Figure 2). There should be a 0.020” to 0.035” clearance measured from
the valley of the starter pinion to the tip of the ring gear tooth. (NOTE: A #1 standard
paper clip is usually about 0.035” in diameter and makes an easy tool.) Check clear-
ance at least three places on the ring gear. If the clearance is too small, add one
shim at a time between the starter and engine block to bring it into specifications.
In many installations, no shims are necessary.
[4] ATTACH BATTERY CABLE AND SWITCH WIRE . The switch wire should be capable of handling 15A, typically a 14AWG wire. The
battery cable must be the proper size for the length of the cable (see chart). All connections should be clean and tight and terminals
should be soldered if possible. The ground cable to the frame should be the same size as the starter cable. Also, a ground strap should
be installed from the frame to the motor. If the original solenoid had a connection to the “R” terminal (ballast resistor bypass), this
wire can usually be eliminated.
(See explanation on the reverse side.)
*Proper mounting of the starter is important because this determines whether the
star
ter pinion will engage properly with the ring gear. When the starter is positioned
correctly, the starter pinion will engage the ring gear without binding and there will
be no chance of starter pinion and/or ring gear damage.
INSTALLATION INSTRUCTIONS
CHEVY STARTERS
7501 Straw Plains Pike • Knoxville, TN 37924
865.688.5953 (fax) 865.281.9844
email: info@powermastermotorspor
ts.com
FIGURE 1
[CONT’D ON REVERSE SIDE]
DISTANCE
AWG
3’
2 1
0
00
5’ 7’ 10’ +10’
4
RING GEAR
PINION
(0.020 - 0.035)
INSERT WIRE
GAUGE HERE
FIGURE 2
CABLE RECOMMENDATIONS
1/16”
OR
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