Installation manual

STARTER MOTOR
DESCRIPTION
The starter can be roughly divided into the following sections:
• A motor section which generates a drive power.
• An overrunning clutch section which transmits an arma-
ture torque, preventing motor overrun after starting.
• A switch section (solenoid) which is operated when actu-
ating the overrunning clutch through a lever and which
supplies load current to the motor.
The starter is a new type, small, light-weight and is called a
high-speed internal-reduction starter. The pinion shaft is
sep-
arate from the motor shaft; the pinion slides only on the pin-
ion shaft. A reduction gear is installed between the motor
shaft and a pinion shaft. The pinion sliding part
is not
exposed outside the starter so that the pinion may slide
smoothly without becoming fouled with dust and grease. The
motor shaft
is supported at both ends on ball bearings. The
lever mechanism, switch and overrunning clutch inner circuit
are identical to conventional ones.
ADJUSTMENT AND REPAIR
If any abnormality is found by the following tests, the starter
should be disassembled and repaired.
Pinion Gap Inspection
1. Connect a battery (12V) between the starter terminalS
and the starter body, and the pinion drive should rotate out
and stop.
A CAUTION: Never apply battery voltage for over 10
seconds continuously.
2. Lightly push the pinion back and measure the return
stroke {called pinion gap).
3. If the pinion gap is not within the standard range, (0.5 to
2.0 mm), adjust it by increasing or decreasing the number
of shims on the solenoid. The gap is decreased as the
number of shims increases.
GENTLY PUSH
BACK ..._,,....---,
0.5-2.0 mm
PINION GAP
39
No-Load Test
1. Connect the ammeter, voltmeter, and battery to the starter
as illustrated.
2. When the switch
is closed, the pinion must protrude and
the starter must run smoothly (at
3000 rpm or more), If
the current or starter speed is out of specification, disas-
semble the starter and repair
it.
e
.------------1 BATTERY
A CAUTION: Use thick wires as much as possible and
tighten every terminal securely. This Is a solenoid shift-
type starter which makes a rotating sound louder than
that of a direct-drive type starter. When detecting
starter rotation at the pinion tip, be careful not to come
in contact with the pinion gear when it protrudes.
SOLENOID
Perform the following tests. If any test result is not
satisfactory, replace the solenoid assembly.
1. Inspect the solenoid for continuity between terminals
( +) and (-) and between terminals S and the body and
M and the body. There should be no continuity found
between terminals S and M. Continuity will be found
between terminals S and the body and terminal M and
the body.
MULTIMETER
NOTE: Disconnect the wire from terminal M.
2. Connect a battery to the solenojd's terminalS for(+)
and M for (-
). Have a switch in the + lead and close it.
The pinion drive should extend fully out.
A CAUTION: Do not apply battery current for more
than 10 seconds when testing the solenoid.