Electrical: Section 2B - Charging & Starting System

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CHARGING & STARTING SYSTEM

ELECTRICAL
Section 2B – Charging & Starting System
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Starter System Components . . . . . . . . . . . 2B-21
2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-21 B
Battery Cable Size . . . . . . . . . . . . . . . . . . . . . . 2B-4 Starter Motor (Model Year 2000) . . . . . . . . . . 2B-22
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . 2B-4 Starter Motor (Model Year 2001) . . . . . . . . . . 2B-24
Recommended Battery . . . . . . . . . . . . . . . . . . . 2B-4 Troubleshooting the Centrifugal Bendix Starter
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-5 Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-26
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-5 Starter Circuit Troubleshooting Flow Chart
Charging a Discharged Battery . . . . . . . . . . . . 2B-5 (Centrifugal Bendix) . . . . . . . . . . . . . . . . . . . . . 2B-27
Winter Storage of Batteries . . . . . . . . . . . . . . . 2B-6 Troubleshooting the Solenoid Driven Bendix
Flywheel Removal and Installation . . . . . . . . . 2B-7 Starter Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-7 Starter Circuit Troubleshooting Flow Chart
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-8 (Solenoid Driven Bendix . . . . . . . . . . . . . . . . . . 2B-30
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9 Starter Removal and Installation (2000 Model) 2B-32
Flywheel/Alternator . . . . . . . . . . . . . . . . . . . . . . 2B-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-32
System Components . . . . . . . . . . . . . . . . . . . . 2B-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-33
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-12 Starter Removal and Installation (2001 Model) 2B-34
Alternator Description . . . . . . . . . . . . . . . . . . . . 2B-13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-34
Diagnosis of Alternator System on Engine . . 2B-13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-35
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-14 Disassembly (Solenoid Driven Bendix Starter) 2B-36
Alternator System Circuitry Test . . . . . . . . . . . 2B-15 Cleaning and Inspection . . . . . . . . . . . . . . . . . . 2B-39
Output Circuit . . . . . . . . . . . . . . . . . . . . . . . . 2B-15 Reassembly (Solenoid Driven Bendix Starter) 2B-40
Sensing Circuit . . . . . . . . . . . . . . . . . . . . . . . 2B-16 Disassembly (Centrifugal Bendix Starter) . . . 2B-44
Voltage Output . . . . . . . . . . . . . . . . . . . . . . . 2B-17 Starter Cleaning, Inspection and Testing . . . 2B-45
Current Output . . . . . . . . . . . . . . . . . . . . . . . 2B-18 Cleaning and Inspection . . . . . . . . . . . . . . . 2B-45
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-19 Testing for Centrifugal Bendix and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-19 Solenoid Driven Bendix Starters . . . . . . . 2B-46
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-20 Reassembly (Centrifugal Bendix Starter) . . . 2B-48
Alternator Belt Tension Adjustment . . . . . . . . 2B-21 Starter Solenoid Test . . . . . . . . . . . . . . . . . . 2B-50
Starter System . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-21 Commander 2000 Key Switch Test . . . . . . . . 2B-51
Starter Motor Amperes Draw . . . . . . . . . . . 2B-21

90-859494R1 JUNE 2000 Page 2B-1


CHARGING & STARTING SYSTEM

Specifications

CHARGING Alternator Output (Regulated) 32 - 38 Amperes @ 2000 RPM @ Battery


SYSTEM 52 - 60 Amperes @ 2000 RPM @
Alternator
Brush Length Std Exposed Length: 0.413 in. (10.5 mm)
Min. Exposed Length: 0.059 in. (1.5 mm)
Voltage Output 13.5 to 15.1 Volts
Regulator Current Draw 0.15 mA (Ign. Switch Off)
30.0 mA (Ign. Switch On)
STARTING Electric Start - All Models
SYSTEM Model Year 2000
Starter Draw (Under Load) 165 Amperes
Starter Draw (No Load) 30 Amperes
Minimum Brush Length 0.25 in. (65.4 mm)

Model Year 2001


Starter Draw (Under Load) 170 Amperes
Starter Draw (No Load) 60 Amperes
Minimum Brush Length 0.25 in. (65.4 mm)

Battery Rating 1000 (Minimum) Marine Cranking Amps


(MCA)
750 (Minimum) Cold Cranking Amps
(CCA)
105 (Minimum) Amp Hour

Page 2B-2 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

Special Tools
1. Volt/Ohm Meter 91-99750A1or DMT 2000 Digital Tachometer Multimeter
91-854009A1

a b

a - Volt/Ohm Meter 91-99750A1


b - DMT 2000 Digital Tachometer Multimeter 91-854009A1

2. Ammeter (60 Ampere minimum) (Obtain locally)


3. Flywheel Holder 91-52344

54964
4. Protector Cap 91-24161

5. Flywheel Puller 91-73687A1

90-859494R1 JUNE 2000 Page 2B-3


CHARGING & STARTING SYSTEM

Battery Cable Size


If standard (original) battery cables are replaced with longer cables, the wire gauge size must increase. See
chart below for correct wire gauge size.

ÎÎ
ÎÎ
Wire Gage Size

Battery Cable Length


Battery Cable Wire Gage Size
Mercury/Mariner Outboards
Battery Cable Length
8 ft. 9 ft. 10ft. 11ft. 12ft. 13ft. 14ft. 15ft. 16ft. 17ft. 18ft. 19ft. 20ft. 21ft. 22ft. 23ft. 24ft.
2.4m 2.7m 3.0m 3.4m 3.7m 4.0m 4.3m 4.6m 4.9m 5.2m 5.5m 5.8m 6.1m 6.4m 6.7m 7.0m 7.3m

Models Wire Gage 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 #6* #4 #4 #4 #4 #4 #2 #2 #2 #2 #2 #2 #2 #2 #0 #0 #0
Hp
125-250 #6* #6 #4 #4 #4 #4 #4 #4 #2 #2 #2 #2 #2 #2 #2
Hp (ex-
cept
DFI)
DFI #4* #2 #2 #2 #2 #2 #2 #2 #2 #2 #0 #0 #0
Models

* = Standard (original) Cable Length and wire gage size.

Replacement Parts
WARNING
Electrical, ignition and fuel system components on your Mercury/Mariner out-
board are designed and manufactured to comply with U. S. Coast Guard Rules
and Regulations to minimize risks of fire and explosions. Use of replacement
electrical, ignition or fuel system components, which do not comply with these
rules and regulations, could result in a fire or explosion hazard and should be
avoided.

Recommended Battery
A 12 volt marine battery with a minimum Cold Cranking amperage rating of 750 amperes
or 1000 (minimum) Marine Cranking amperes should be used.

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CHARGING & STARTING SYSTEM

Battery
Precautions
CAUTION
If battery acid comes in contact with skin or eyes, wash skin immediately with a
mild soap. Flush eyes with water immediately and see a doctor.
When charging batteries, an explosive gas mixture forms in each cell. Part of this gas es-
capes through holes in vent plugs and may form an explosive atmosphere around battery
if ventilation is poor. This explosive gas may remain in or around battery for several hours
after it has been charged. Sparks or flames can ignite this gas and cause an internal ex-
plosion which may shatter the battery.
The following precautions should be observed to prevent an explosion.
1. DO NOT smoke near batteries being charged or which have been charged very re-
cently.
2. DO NOT break live circuits at terminals of batteries because a spark usually occurs
at the point where a live circuit is broken. Always be careful when connecting or dis-
connecting cable clamps on chargers. Poor connections are a common cause of elec-
trical arcs which cause explosions.
3. DO NOT reverse polarity of battery terminal to cable connections.

Charging a Discharged Battery


WARNING
Hydrogen and oxygen gases are produced during normal battery operation or
charging. Sparks or flame can cause this mixture to ignite and explode, if they are
brought near the vent openings. Sulphuric acid in battery can cause serious
burns, if spilled on skin or in eyes. Flush or wash away immediately with clear
water.
The following basic rule applies to any battery charging situation:
1. Any battery may be charged at any rate (in amperes) or as long as spewing of electro-
lyte (from violent gassing) does not occur and for as long as electrolyte temperature
does not exceed 125° F (52° C). If spewing of electrolyte occurs, or if electrolyte tem-
perature exceeds 125° F, charging rate (in amperes) must be reduced or temporarily
halted to avoid damage to the battery.
2. Battery is fully charged when, over a 2-hour period at a low charging rate (in amperes),
all cells are gassing freely (not spewing liquid electrolyte), and no change in specific
gravity occurs. Full charge specific gravity is 1.260-1.275, corrected for electrolyte
temperature with electrolyte level at 3/16 in. (4.8 mm) over plate, unless electrolyte
loss has occurred (from age or over-filling) in which case specific gravity reading will
be lower. For most satisfactory charging, lower charging rates in amperes are recom-
mended.
3. If, after prolonged charging, specific gravity of at least 1.230 on all cells cannot be
reached, battery is not in optimum condition and will not provide optimum perform-
ance; however, it may continue to provide additional service, if it has performed satis-
factorily in the past.

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CHARGING & STARTING SYSTEM

4. To check battery voltage while cranking engine with electric starting motor, place RED
(+) lead of tester on POSITIVE (+) battery terminal and BLACK (–) lead of tester on
NEGATIVE (–) battery terminal. If the voltage drops below 9-1/2 volts while cranking,
the battery is weak and should be recharged or replaced.

Winter Storage of Batteries


Battery companies are not responsible for battery damage either in winter storage or in
dealer stock if the following instructions are not observed:
1. Remove battery from its installation as soon as possible and remove all grease, sul-
fate and dirt from top surface by running water over top of battery. Be sure, however,
that vent caps are tight beforehand, and blow off all excess water thoroughly with com-
pressed air. Check water level, making sure that plates are covered.
2. When adding distilled water to battery, be extremely careful not to fill more than 3/16
in. (4.8 mm) above perforated baffles inside battery. Battery solution or electrolyte ex-
pands from heat caused by charging. Overfilling battery will cause electrolyte to over-
flow (if filled beyond 3/16″ above baffles).
3. Grease terminal bolts well with 2-4-C Marine Lubricant and store battery in a COOL-
DRY place. Remove battery from storage every 30-45 days, check water level and
put on charge for 5 or 6 hours at 6 amperes. DO NOT FAST CHARGE.
4. If specific gravity drops below 1.240, check battery for reason and recharge. When
gravity reaches 1.260, discontinue charging. To check specific gravity, use a hydrom-
eter, which can be purchased locally.
5. Repeat preceding charging procedure every 30-45 days, as long as battery is in stor-
age, for best possible maintenance during inactive periods to ensure a good service-
able battery in spring. When ready to place battery back in service, remove excess
grease from terminals (a small amount is desirable on terminals at all times), recharge
again as necessary and reinstall battery.

Page 2B-6 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

Flywheel Removal and Installation


Removal
1. Remove flywheel cover from engine.

WARNING
Engine could possibly start when turning flywheel during removal and installa-
tion; therefore, disconnect (and isolate) spark plug leads from spark plugs to pre-
vent engine from starting.
2. Disconnect spark plug leads from spark plugs.
3. While holding flywheel with flywheel holder (91-52344), remove flywheel nut and
washer.

57529

a - Flywheel Holder (91-25344)

4. Install a crankshaft Protector Cap (91-24161) on end of crankshaft, then install Fly-
wheel Puller (91-73687A2) into flywheel.
5. Hold flywheel tool with wrench while tightening bolt down on protector cap. Tighten
bolt until flywheel comes free.

57528

a - Flywheel Puller (91-73687A2)

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CHARGING & STARTING SYSTEM

NOTE: Neither heat or hammer should be used on flywheel to aid in removal as damage
to flywheel or electrical components under flywheel may result.
6. Remove flywheel. Inspect flywheel for cracks or damage.

Installation
IMPORTANT: Clean flywheel/crankshaft taper with solvent and assemble dry.
1. Install flywheel.
2. Install flywheel washer and nut.
3. Hold flywheel with Flywheel Holder (91-52344). Torque nut to 125 lb-ft (169.5 Nm).

57527

a - Flywheel Holder (91-52344)

Page 2B-8 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

Notes:

90-859494R1 JUNE 2000 Page 2B-9


CHARGING & STARTING SYSTEM

Flywheel/Alternator
22
18
21
23 17

20

19
95
20
27

16
25 95

15
26

24
3

2
4

10
6

11
7

7
12

13 7 5
5
8

14 4

9
4
95 2-4-C With Teflon (92-825407A12) 14 9

Page 2B-10 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

Flywheel/Alternator
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 ALTERNATOR
2 1 SCREW (M10 x 100) 480 40 54
3 1 SCREW (M10 x120) 480 40 54
4 3 WASHER
5 3 MOUNT
6 1 BRACKET
7 3 WASHER
8 1 BRACKET
9 2 NUT 480 40 54
10 1 SCREW (M10 x 55) 480 40 54
11 1 CABLE
12 1 PIN
13 1 BRACKET
14 3 SCREW (5/16-18 x 1 IN.) 185 15.5 21
15 1 SPRING
16 1 BELT TENSIONER ARM ASSY
17 1 STUD (M10 x 85)
18 1 NUT 180 15 20
19 1 BUSHING
20 2 WASHER
21 1 PULLEY
22 1 SCREW (M10 x 35) 300 25 34
23 1 BELT
24 1 FLYWHEEL
25 1 NUT (M16X1.5) 125 170
26 1 WASHER
27 1 PLUG

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CHARGING & STARTING SYSTEM

System Components
The battery charging system consists of the alternator, battery, ignition switch, starter so-
lenoid and the wiring which connects these components.

aa

dd

bb
To
51708
a - Alternator
b - Battery
c - 20 Ampere Fuse
d - Starter Solenoid

Precautions
The following precautions must be observed when working on the alternator system. Fail-
ure to observe these precautions may result in serious damage to the alternator system.
1. Do not attempt to polarize the alternator.
2. Do not short across or ground any of the terminals on the alternator, except as specifi-
cally instructed.
3. Never disconnect the alternator output lead, regulator harness or battery cables when
the alternator is being driven by the engine.
4. Always remove NEGATIVE (–) battery cable from battery before working on alternator
system.
5. When installing battery, be sure to connect the NEGATIVE (–) (GROUNDED) battery
cable to NEGATIVE (–) battery terminal and the POSITIVE (+) battery cable to POSI-
TIVE (+) battery terminal.
6. When using a charger or booster battery, connect it in parallel with existing battery
(POSITIVE to POSITIVE; NEGATIVE to NEGATIVE).

Page 2B-12 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

Alternator Description
The alternator employs a rotor, which is supported in 2 end frames by ball bearings, and
is driven at 2.5 times engine speed. The rotor contains a field winding enclosed between
2 multiple-finger pole pieces. The ends of the field winding are connected to 2 brushes
which make continuous sliding contact with the slip rings. The current (flowing through
the field winding) creates a magnetic field that causes the adjacent fingers of the pole
pieces to become alternate north and south magnetic poles.
A 3-phase stator is mounted directly over the rotor pole pieces and between the 2 end
frames. It consists of 3 windings wound 120° electrically out-of-phase on the inside of a
laminated core. The windings are connected together on one end, while the other ends
are connected to a full-wave rectifier bridge.
The rectifier bridge contains 8 diodes which allows current to flow from ground, through
the stator and to the output terminal, but not in the opposite direction.
When current is supplied to the rotor field winding, and the rotor is turned, the movement
of the magnetic fields created induces an alternating current into the stator windings. The
rectifier bridge changes this alternating current to direct current which appears at the out-
put terminal. A diode trio is connected to the stator windings to supply current to the regu-
lator and the rotor field during operation.
Voltage output of the alternator is controlled by a transistorized voltage regulator that
senses the voltage at the battery and regulates the field current to maintain alternator volt-
age for properly charging the battery. Current output of the alternator does not require reg-
ulation, as maximum current output is self-limited by the design of the alternator. As long
as the voltage is regulated within the prescribed limits, the alternator cannot produce ex-
cessive current. A cutout relay in the voltage regulator also is not required, as the rectifier
diodes prevent the battery from discharging back through the stator.
A small amount of current is supplied by the excitation circuit in the regulator to the rotor
field to initially start the alternator charging. Once the alternator begins to produce output,
field current is supplied solely by the diode trio.
The alternator is equipped with 2 fans which induce air flow through the alternator to re-
move heat created by the rectifier and stator.

Diagnosis of Alternator System on Engine


1. If problem is an undercharged battery, verify condition has not been caused by exces-
sive accessory current draw or by accessories which have accidentally been left on.
2. Check physical condition and state of charge of battery. Battery must be at least 75%
(1.230 specific gravity) of fully charged to obtain valid results in the following tests. If
not, charge battery before testing system.
3. Inspect entire alternator system wiring for defects. Check all connections for tightness
and cleanliness, particularly battery cable clamps and battery terminals.
IMPORTANT: RED output lead from alternator must be tight. A darkened RED
sleeve indicates lead was loose and becoming hot.
4. Check alternator drive belt for cracks and fraying. Replace if necessary. Check belt
tension. Adjust if necessary, as outlined under “Drive Belt Replacement and Adjust-
ment.”

90-859494R1 JUNE 2000 Page 2B-13


CHARGING & STARTING SYSTEM

Notes:

Page 2B-14 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

Alternator System Circuitry Test


Using a 0-20 volt DC voltmeter, perform the following tests:
Output Circuit
1. Connect POSITIVE (+) voltmeter lead to alternator terminal B (output terminal). Con-
nect NEGATIVE (–) lead to case ground on alternator.
2. Shake alternator wiring harness. Meter should indicate battery voltage and should not
vary. If proper reading is not obtained, check for loose or dirty connections or dam-
aged wiring.

13.65

57692

57692

a - Terminal B

90-859494R1 JUNE 2000 Page 2B-15


CHARGING & STARTING SYSTEM

Sensing Circuit
1. Unplug RED and PURPLE lead connector from alternator.
2. Connect POSITIVE (+) voltmeter lead to RED lead and NEGATIVE (–) voltmeter lead
to ground.
3. Voltmeter should indicate battery voltage. If correct voltage is not present, check
sensing circuit (RED lead) for loose or dirty connections or damaged wiring.

58458
13.65

c
a

57961

b
a - Sense Lead (RED)
b - Model Year 2000 Connector
c - Model Year 2001 Connector

Page 2B-16 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

Voltage Output
1. Using a 0-20 volt DC voltmeter, connect POSITIVE (+) lead of voltmeter to TERMINAL
B of alternator and NEGATIVE (–) lead of voltmeter to engine ground.
2. Start engine and allow to warm up. Increase engine RPM from idle to 2000. Normal
voltage output should be 13.5 – 15.1 volts. If voltage reading is greater than normal,
replace voltage regulator.
3. If voltage reading is less than normal, fabricate a tool from a piece of stiff wire to the
following specifications:

13.65
0.060 in. (1.52 mm)

57692
8 in. (203 mm)

13/16 in. (20.6 mm)

57692
a - Terminal B

4. Insert bent end of tool through end cover and ground TERMINAL F.

a
b

a
c
51683

57693
a - Terminal F
b - Tool
c - Jumper Wire to Engine Ground (Attach to end of Tool)

5. With TERMINAL F grounded, voltage should rise to within the normal range (13.5 –
15.1). If voltage rises, replace the regulator.
6. If the voltage DOES NOT rise to within the normal range with TERMINAL F grounded,
perform “CURRENT OUTPUT” test.

90-859494R1 JUNE 2000 Page 2B-17


CHARGING & STARTING SYSTEM

Current Output
1. With engine shut off, install ammeter (capable of reading 60+ amperes) in series be-
tween TERMINAL B on alternator and POSITIVE (+) terminal of battery.
2. Start engine and allow to warm up. Advance RPM to 2000.
3. Insert tool, previously fabricated for VOLTAGE OUTPUT, through end cover and
ground TERMINAL F.

d
a
b

57964

a - Terminal F d - Terminal B
b - Tool e - Ammeter
c - Jumper Wire to Engine
Ground
4. Normal output is 52 – 60 amperes @ 2000 RPM @ the alternator. If output is normal,
replace regulator. If output is low, a disassembly of the alternator is necessary to in-
spect and test individual components.

Page 2B-18 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

Repair
Removal
1. Remove top cowling.
2. Disconnect battery cables from battery.
3. Disconnect wiring harness from alternator.
4. Remove pivot bolt and tension bolt.

a
b

57539
a - Attaching Bolt b - Harnesses

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CHARGING & STARTING SYSTEM

Installation
1. Secure alternator to engine block with attaching bolts. Torque top bolt to 40 lb-ft (54
Nm). Torque bottom bolt to 35 lb-ft (47.5 Nm).
2. Install alternator belt in V-groove of flywheel and alternator pulley.
3. Reconnect electrical harness to alternator.

c
b

57539

a - Top Bolt [Torque to 40 lb-ft (54 Nm)]


b - Bottom Nut [Torque to 35 lb-ft. (47.5 Nm)
c - Harnesses

Page 2B-20 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

Alternator Belt Tension Adjustment


Correct alternator belt tension is maintained by a belt tensioner assembly.

57489
a - Belt Tensioner Assembly

Starter System
Starter Motor Amperes Draw
STARTER MOTOR NO LOAD NORMAL
PART NO. AMP. DRAW AMP. DRAW
50-833153-1 30 AMPS 165 AMPS
50-853329-1 60 AMPS 170 AMPS
Starter System Components
a - Battery d - Starter Motor
b - Starter Solenoid e - Ignition Switch
c - Neutral Start Switch f - Slave Solenoid (Model
Year 2001)
Description
The battery supplies electricity to activate the starter motor. When the ignition is turned
to the “START” position, the starter solenoid is energized and completes the starter circuit
between the battery and starter.
Model year 2001 engines incorporate a slave solenoid to activate the starter solenoid.
The neutral start switch opens the starter circuit when the shift control lever is not in neu-
tral thus preventing accidental starting when the engine is in gear.

CAUTION
The starter motor may be damaged if operated continuously. DO NOT operate
continuously for more than 30 seconds. Allow a 2 minute cooling period between
starting attempts.

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CHARGING & STARTING SYSTEM

Starter Motor (Model Year 2000)(Centrifugal Bendix)

18

17 4

3
20 5
15

19

2
1

14

22 21
10
17
7
8
6
9

16
7

11
14 13 12

14 Formula 50 2 Cycle Motor Oil

Page 2B-22 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

Starter Motor (Model Year 2000)(Centrifugal Bendix)


TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. 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 LOCKWASHER
12 1 NUT (1/4-20) 35 4.0
13 1 LOCKWASHER
14 1 NUT (1/4-20) 35 4.0
15 1 DECAL-Warning-High Voltage
16 1 BOOT
17 2 COLLAR
18 2 RUBBER STOP
19 1 SCREW (1/4-20 x 5/8) 80 9.0
20 1 WIRE ASSEMBLY (BLACK)
21 1 LOCKWASHER
22 1 NUT 60 7.0

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CHARGING & STARTING SYSTEM

Starter Motor (Model Year 2001)(Solenoid Driven Bendix)


1
3
2

5
4

12 14

13
9

10
11

23 15
24
16 18

24
25
17

21 19
20

21

22
22 58430

Page 2B-24 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

Starter Motor (Model Year 2001)(Solenoid Driven Bendix)


TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-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

90-859494R1 JUNE 2000 Page 2B-25


CHARGING & STARTING SYSTEM

Troubleshooting the Centrifugal Bendix Starter Circuit


Before beginning the troubleshooting flow chart, verify the following conditions:
1. Confirm that battery is fully charged.
2. Check that control lever is in “NEUTRAL” position.
3. Check terminals for corrosion and loose connections.
4. Check cables and wiring for frayed and worn insulation.
5. Check 20 amp fuse.
Location of “Test Points” (called out in flow chart) are numbered below.

STARTER
TO ALTERNATOR

BATTERY

77
22
11

20 AMP FUSE 66
33
STARTER
SOLENOID
44

55

NEUTRAL START SWITCH


IGNITION SWITCH (LOCATED IN CONTROL HOUSING)

Centrifugal Bendix Starter Circuit

Page 2B-26 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

Starter Circuit Troubleshooting Flow Chart (Centrifugal


Bendix)
Starter Motor Does Not Turn

SAFETY WARNING: Disconnect yellow (starter motor)


cable from starter solenoid test point 1 BEFORE making
tests 1–thru–7 to prevent unexpected engine cranking.

TEST 1
Use an ohmmeter (Rx1 scale) and connect meter leads
between NEGATIVE (–) battery post and common power-
head ground.

No Continuity Indicated – There is an open circuit in the Continuity Indicated


BLACK NEGATIVE (–) battery cable between the NEGATIVE (–) Proceed to TEST 2
battery post and the powerhead.
• Check cable for loose or corroded connections.
• Check cable for open.

Test 2
a. Disconnect BLACK ground wire(s) from Test Point 2.
No voltage reading: b. Connect voltmeter between common engine ground and Test Point 2.
proceed to TEST 3. c. Turn ignition key to “Start” position.

TEST 3 12 Volt Reading*


a. Reconnect BLACK ground wire. Check BLACK ground wire for poor connection
b. Connect voltmeter between common engine ground and Test Point 3. or open circuit.
Reconnect ground wire to starter solenoid.
c. Turn ignition key to “Start” position. Proceed to TEST 7.

No voltage reading: 12 Volt Reading


proceed to Step 4 Defective starter solenoid

TEST 4
a. Connect voltmeter between common 12 Volt Reading*
engine ground and Test Point 4. Neutral start switch is open or YELLOW/RED
No voltage reading: wire is open between Test Points 4 and 3.
proceed to Test 5 b. Turn ignition key to “Start” position.

TEST 5
Connect voltmeter between common 12 Volt Reading*
No voltage reading:
engine ground and Test Point 5 Defective ignition switch.
proceed to Test 6

TEST 6
Check for voltage between common engine ground and Test Point 6.

No voltage reading: 12 Volt Reading*


Check RED wire between battery(+) Check fuse in RED wire between Test
POSITIVE terminal and Test Point 6. Points 5 and 6.
Check for open RED wire between Test
Points 5 and 6.

*Battery Voltage

90-859494R1 JUNE 2000 Page 2B-27


CHARGING & STARTING SYSTEM

TEST 7
a. Connect voltmeter between common engine and Test Point1.
b. Turn ignition key to “Start” position.

No voltage reading: 12 Volt Reading*


Defective starter solenoid Should hear solenoid click: proceed to TEST 8

TEST 8
a. Reconnect BLACK cable (with YELLOW sleeve) to starter solenoid Test
Point 1.
b. Connect voltmeter between common engine ground and Test Point 7.
c. Turn ignition key to “Start” position.

No voltage reading:
Check BLACK cable (with YELLOW
12 Volt Reading*
sleeve) for poor connection or open circuit. If starter motor does not turn, check starter motor.

*Battery Voltage

Page 2B-28 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

Troubleshooting the Solenoid Driven Bendix Starter Circuit


Before beginning the troubleshooting flow chart, verify the following conditions:
1. Confirm that battery is fully charged.
2. Check that control lever is in “NEUTRAL” position.
3. Check terminals for corrosion and loose connections.
4. Check cables and wiring for frayed and worn insulation.
5. Check 20 amp fuse.
Location of “Test Points” (called out in flow chart) are numbered below.

10
TO ALTERNATOR
9
8
1
STARTER
BATTERY
STARTER
SOLENOID

4
2

SLAVE SOLENOID

20 AMP FUSE 3
7

6 5

IGNITION SWITCH
NEUTRAL START SWITCH

(LOCATED IN CONTROL HOUSING)

58431
Solenoid Driven Bendix Starter Circuit

90-859494R1 JUNE 2000 Page 2B-29


CHARGING & STARTING SYSTEM

Starter Circuit Troubleshooting Flow Chart (Solenoid


Driven Bendix
Starter Motor Does Not Turn

TEST 1
With ignition key in START position, check for battery volt-
age at TEST POINT 1.

Voltage indicated and solenoid clicks No voltage indicated Voltage indicated and solenoid does not click

Go to TEST 2 Check for starter motor ground at Test Point 10


Voltage indicated at Test Point 9
is 9.5 volts or greater.

Good ground Bad ground – clean cable ends


Voltage indicated at Test Point 9 or replace ground cable
is less than 9.5 volts.

Defective starter solenoid


Defective starter motor Defective starter solenoid

SAFETY WARNING: Disconnect BLACK with RED sleeve (starter motor)


cable from slave solenoid test point 7 BEFORE making tests 1–thru–7 to
prevent unexpected engine cranking.

TEST 2
Use an ohmmeter (Rx1 scale) and connect meter leads
between NEGATIVE (–) battery post and common power-
head ground.

No Continuity Indicated – There is an open circuit in the Continuity Indicated


BLACK NEGATIVE (–) battery cable between the NEGATIVE (–) Proceed to TEST 3
battery post and the powerhead.
• Check cable for loose or corroded connections.
• Check cable for open.

Test 3
a. Disconnect BLACK ground wire(s) from Test Point 3.
No voltage reading: b. Connect voltmeter between common engine ground and Test Point 3.
proceed to TEST 4. c. Turn ignition key to “Start” position.

TEST 4 12 Volt Reading*


a. Reconnect BLACK ground wire. Check BLACK ground wire for poor connection
b. Connect voltmeter between common engine ground and Test Point 4. or open circuit.
Reconnect ground wire to starter solenoid.
c. Turn ignition key to “Start” position. Proceed to TEST 8.

Page 2B-30 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

No voltage reading: 12 Volt Reading


proceed to TEST 5 Defective starter solenoid

TEST 5
a. Connect voltmeter between common 12 Volt Reading*
engine ground and Test Point 5. Neutral start switch is open or YELLOW/RED
No voltage reading: wire is open between Test Points 5 and 4.
proceed to TEST 6 b. Turn ignition key to “Start” position.

TEST 6
Connect voltmeter between common 12 Volt Reading*
No voltage reading:
engine ground and Test Point 6 Defective ignition switch.
proceed to TEST 7

TEST 7
Check for voltage between common engine ground and Test Point 7.

No voltage reading: 12 Volt Reading*


Check BLACK cable with RED Check fuse in RED wire between Test Points
sleeve between battery(+) 6 and 7.
POSITIVE terminal and Test Point 8 Check for open RED wire between Test
and Test Point 7. Points 6 and 7.

TEST 8
a. Connect voltmeter between common engine ground and Test Point 2.
b. Turn ignition key to “Start” position.

No voltage reading: 12 Volt Reading*


Defective slave solenoid Should hear solenoid click: proceed to TEST 9

TEST 9
a. Reconnect BLACK cable (with RED sleeve) to slave solenoid Test
Point 7.
b. Connect voltmeter between common engine ground and Test Point 7.
c. Turn ignition key to “Start” position.

No voltage reading:
Check BLACK cable (with RED sleeve) for
poor connection or open circuit.

*Battery Voltage

90-859494R1 JUNE 2000 Page 2B-31


CHARGING & STARTING SYSTEM

Starter Removal and Installation (2000 Model)


Removal
CAUTION
Disconnect battery leads from battery before removing starter.
1. Disconnect BLACK ground cable from starter.
2. Disconnect BLACK cable (with YELLOW sleeve – 2000 Model) from starter.
3. Remove 2 upper bolts and 2 lower bolts securing starter and remove starter.

a - BLACK (with YELLOW b - Upper Mounting Bolts


sleeve) POSITIVE (+) c - Lower Mounting Bolts
12-Volt Cable

Page 2B-32 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

Installation
1. Secure starter to engine with 4 bolts. Use Left top bolt to attach BLACK NEGATIVE
(–) battery cable.
Torque top attaching bolts to 23 lb-ft (31 Nm). Torque bottom attaching bolts to 21 lb-ft
(28.5 Nm).
2. Secure BLACK cable (with YELLOW sleeve) to POSITIVE (+) terminal on starter.
Torque nut to 60 lb-in (7 Nm).
a

57685

a - Top Bolts [Torque to 23 lb-ft (31 Nm)]


b - Bottom Bolts [Torque to 21 lb-ft (28.5 Nm)]
c - BLACK Cable (with YELLOW sleeve)
d - Nut [Torque to 60 lb-in (7 Nm)]

90-859494R1 JUNE 2000 Page 2B-33


CHARGING & STARTING SYSTEM

Starter Removal and Installation (2001 Model)


Removal
CAUTION
Disconnect battery leads from battery before removing starter.
1. Disconnect battery cables from battery.
2. Disconnect wires from starter solenoid terminals.
3. Remove starter trunion mounting bolts and remove starter from engine.

58428

a - Starter Solenoid
b - Mounting Bolts

Page 2B-34 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

Installation
1. Secure starter to engine with 4 bolts. Use right top bolt to attach BLACK NEGATIVE.
Torque top attaching bolts to 23 lb-ft (31 Nm). Torque bottom attaching bolts to 21 lb-ft.
(28.5 Nm).
2. Secure BLACK cables (with RED sleeveS) to POSITIVE (+) terminal on starter sole-
noid. Torque nut to 55 lb-in (6 Nm).

e
c

b d

58428
a - Top Bolts [Torque to 23 lb-ft (31 Nm)]
b - Bottom Bolts [Torque to 21 lb-ft (28.5 Nm)]
c - BLACK Cables (with RED sleeves)
d - Nut [Torque to 55 lb-in (6 Nm)]
e - Starter Solenoid

90-859494R1 JUNE 2000 Page 2B-35


CHARGING & STARTING SYSTEM

Disassembly (Solenoid Driven Bendix Starter)


1. Remove brush lead from solenoid and through bolts from end frame.

e
b

a
c

58434
a - Brush Lead d - Brush Plate Screws
b - Through Bolts e - End Frame
c - Starter Solenoid
2. Remove armature and field frame from drive housing.
NOTE: Permanent magnets inside field frame will be holding armature in place.

d
e
58430
a - End Frame and Bearing
b - Screws (2) [Internal Torx – Snap On E6 Socket]
c - Brush Holder
d - Armature
e - Field Frame

Page 2B-36 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

3. Remove shield and cushion from drive housing.

58432

a - Shield
b - Cushion
c - Drive Housing
4. Remove 3 screws retaining starter solenoid. Remove solenoid from drive housing.
5. Remove snap ring and gear from starter shaft.

b
d

58436
a - Drive Housing d - Snap Ring
b - Starter Solenoid e - Pinion Gear
c - Screws (3) [ Internal
Torx– Snap On E6
Socket]

90-859494R1 JUNE 2000 Page 2B-37


CHARGING & STARTING SYSTEM

6. Remove planetary gear and clutch assembly from drive housing.


7. Remove solenoid arm, metal disc and plug from drive housing.

d
c

58437
a - Planetary Gear and d - Metal Disc
Clutch Assembly e - Solenoid Arm
b - Drive Housing
c - Plug
8. Inspect drive housing needle bearing for roughness. If bearing is worn or damaged,
bearing can be removed by using an appropriate mandrel to drive/press bearing from
drive housing.
NOTE: If bearing has spun in drive housing bore, drive housing must be replaced.

58439

a - Needle Bearing
b - Drive Housing

Page 2B-38 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

Cleaning and Inspection


IMPORTANT: Do not use grease dissolving solvents to clean electrical compo-
nents, planetary gears or drive clutch. Solvent will damage insulation and wash the
lubricant out of the clutch drive and gears. Use clean rags and compressed air to
clean components.
1. Test over-running clutch action of drive. Pinion should turn freely in over-running di-
rection and must not slip in cranking direction.
2. Inspect pinion teeth for wear.
3. Inspect spring for tension and drive collar for wear.
4. Check that bearings roll freely. If any roughness is felt, replace bearing.
5. Inspect planetary gear assembly. Gears must mesh easily and roll freely with no bind-
ing.

90-859494R1 JUNE 2000 Page 2B-39


CHARGING & STARTING SYSTEM

Reassembly (Solenoid Driven Bendix Starter)


1. Install solenoid arm with planetary gear and clutch assembly into drive housing.

b
58438

a - Solenoid Arm
b - Planetary Gear and Clutch Assembly
c - Drive Housing
2. Install metal disc and plug into drive housing.

a
b

58433
a - Metal Disc
b - Plug

Page 2B-40 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

3. Attach solenoid arm to starter solenoid. Install starter solenoid in drive housing and
secure with 3 screws. Torque screws to 40 lb-in (4.5 N.m).
4. Install drive gear and secure with snap ring.
5. Reinstall rubber bumpers on housing.

c
e
a

58436
a - Drive Housing d - Drive Gear
b - Starter Solenoid e - Snap Ring
c - Screw (3) [Torque to f - Bumpers
40 lb-in (4.5 N.m)
6. Install cushion and shield in drive housing.
c

58432
a - Shield
b - Cushion
c - Drive Housing

90-859494R1 JUNE 2000 Page 2B-41


CHARGING & STARTING SYSTEM

7. Install field frame over armature.


8. While holding brushes back, slide brush plate onto armature while aligning brush lead
grommet with slot in field frame.
9. Secure end plate to brush assembly with 2 screws. Torque screws to 30 lb-in (3.4 Nm)
NOTE: Prior to installing field frame assembly into drive housing, align slot in field frame
with plug in drive housing.

d
c

58435

a - Armature
b - Field Frame Grommet Slot
c - Brush Plate
d - Brush Lead Grommet
e - End Plate
f - Screws [Torque to 30 lb-in (3.4 Nm)]
g - Field Frame Plug Slot

Page 2B-42 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

10. Install field frame and end frame in drive housing.


11. Install through bolts and brush lead. Torque through bolts to 110 lb-in (12.5 Nm).
Torque brush nut to 55 lb-in (6 Nm).

b
d c

f
a
58434
a - End Frame
b - Field Frame
c - Drive Housing
d - Through Bolts [Torque to 110 lb-in (12.5 Nm)]
e - Brush Lead
f - Brush Nut [Torque to 55 lb-in (6 Nm)]

90-859494R1 JUNE 2000 Page 2B-43


CHARGING & STARTING SYSTEM

Disassembly (Centrifugal Bendix Starter)


1. Remove starter as outlined in “Starter Removal and Installation,” preceding.
2. Remove 2 through bolts from starter.
3. Tap commutator end cap to loosen and remove from frame. Do not loose brush
springs.
aa

11646
a - Through Bolts b - Commutator End Cap
4. Brush replacement is recommended if brushes are pitted, chipped or worn to less than
0.25 in. (6.4 mm). If necessary, remove brushes as follows:
a. Remove hex nut and washers from POSITIVE (+) terminal and remove POSITIVE
brushes and terminal as an assembly.
b. Remove 2 bolts securing NEGATIVE (–) brushes and brush holder to end cap.

a cc
bb

c
d bb 11656
a - Brush Holder
b - Positive Brushes
c - Negative Brushes
d - Positive Terminal

Page 2B-44 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

5. Remove armature (with drive end cap) from starter frame.


6. Remove locknut and remove drive assembly from armature shaft.
ef hg
gf

ed

aa ba c
b dc

51711 11658

a - Hold Armature Shaft with Wrench on Hex Portion of Drive Assembly


b - Locknut
c - Spacer
d - Spring
e - Drive Assembly
f - Drive End Cap
g - Armature Shaft
h - Washer

Starter Cleaning, Inspection and Testing


Cleaning and Inspection
1. Clean all starter motor parts.
2. Check pinion teeth for chips, cracks or excessive wear.
3. Replace the drive clutch spring and/or collar if tension is not adequate or if wear is
excessive.
4. Inspect brush holder for damage or for failure to hold brushes against commutator.
5. Replace brushes that are pitted or worn to less than 1/4 in. (6.4 mm) in length.
6. Inspect the armature conductor (commutator bar junction) for a tight connection. A
loose connection (excessive heat from prolonged cranking melts solder joints) results
in a burned commutator bar.
7. Resurface and undercut a rough commutator as follows:

CAUTION
Do not turn down the commutator excessively.
a. Resurface the commutator and undercut the insulation between the commutator
bars 1/32 in. (0.8mm) to the full width of the insulation and so that the undercut
is flat.
b. Clean the commutator slots after undercutting.
c. Sand the commutator lightly with No. 00 sandpaper to remove burrs, then clean
the commutator.

90-859494R1 JUNE 2000 Page 2B-45


CHARGING & STARTING SYSTEM

d. Recheck the armature on a growler for shorts as specified in the following proce-
dure (“Testing”).
8. Open-circuited armatures often can be repaired. The most likely place for an open
circuit is at the commutator bars, as a result of long cranking periods. Long cranking
periods overheat the starter motor so that solder in the connections melts and is
thrown out. The resulting poor connections then cause arcing and burning of the com-
mutator bars.
9. Repair bars, that are not excessively burned, by resoldering the leads in bars (using
rosin flux solder) and turning down the commutator in a lathe to remove burned mate-
rial, then undercut the mica.
10. Clean out the copper or brush dust from slots between the commutator bars.
11. Check the armature for ground. See the following procedure (“Testing”).
Testing for Centrifugal Bendix and Solenoid Driven Bendix Starters
Armature Test for Shorts
Check armature for short circuits by placing on growler and holding hack saw blade over
armature core while armature is rotated. If saw blade vibrates, armature is shorted.
Recheck after cleaning between commutator bars. If saw blade still vibrates, replace
armature.

11669
Armature Test for Ground
1. Set ohmmeter to (R x 1 scale). Place one lead of ohmmeter on armature core or shaft
and other lead on commutator.
2. If meter indicates continuity, armature is grounded and must be replaced.

51711

Page 2B-46 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

Checking Positive Brushes and Terminal


Set ohmmeter to (R x 1 scale). Connect meter leads between POSITIVE brushes. Meter
must indicate full continuity or zero resistance. If resistance is indicated, inspect lead to
brush and lead to POSITIVE terminal solder connection. If connection cannot be repaired,
brushes must be replaced.

51711
a - POSITIVE (+) Brushes
Testing Negative Brushes for Ground
Set ohmmeter to (R x1 scale). Place one lead of the ohmmeter on the NEGATIVE brush
and the other lead on the end cap (bare metal). If the meter indicates NO continuity, re-
place the NEGATIVE brush. Repeat this procedure on the other NEGATIVE brush.

bb

a - NEGATIVE (–) Brushes


b - End Cap

90-859494R1 JUNE 2000 Page 2B-47


CHARGING & STARTING SYSTEM

Starter Reassembly (Centrifugal Bendix Starter)


1. If brushes were removed, replace as follows:
a. Install POSITIVE brushes (along with POSITIVE terminal) into commutator end
cap.

aa
b hb

cc
ci
d
d
ee ga
51713
ff
52131
a - End Cap
b - POSITIVE Brushes
c - POSITIVE Terminal
d - Insulating Block
e - Insulating Washer
f - Hex Nut
g - POSITIVE (+) Terminal
h - Long Brush Lead
i - Push Lead into Slot

b. Install NEGATIVE brushes (along with brush holder).

bb
aa c

dd
dd

b a 11656
a - POSITIVE (+) Brushes
b - NEGATIVE (–) Brushes
c - Brush Holder
d - Bolts (Fasten NEGATIVE Brushes and Holder)

Page 2B-48 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

2. If removed, reinstall parts on armature shaft. Use a new locknut and tighten securely
on end of shaft.
d
d
ee gg
a b ff
c

11658
a - Locknut
b - Spacer
c - Spring
d - Drive Assembly
e - Drive End Cap
f - Armature Shaft
g - Washer

3. Lubricate helix threads on armature shaft with a drop of SAE 10W oil.
4. Lubricate bushing in drive end plate with a drop of SAE 10W oil.
5. Position armature into starter frame.
6. Lubricate bushing (located in commutator end cap) with one drop of SAE 10W oil. DO
NOT overlubricate.
7. To prevent damage to brushes and springs when installing commutator end cap, it is
recommended that a brush retaining tool be made as shown:

1-3/4″
(44.5 mm)

2-1/6″ 9/16″ (14.3 mm)


(55.1 mm)

aa

5″
(127.0 mm)

a - Bushing (DO NOT overlubricate)

90-859494R1 JUNE 2000 Page 2B-49


CHARGING & STARTING SYSTEM

8. Place springs and brushes into brush holder and hold in place with brush retainer tool.
9. Install commutator end cap onto starter frame. Align marks on frame with alignment
marks on end caps. Remove brush retainer tool. Install through bolts and torque to
70 lb. in. (8 Nm).

ba

51713
52130
a - Brush Retainer Tool
b - Alignment Marks

Starter Solenoid Test


1. Disconnect all wires from solenoid.
2. Connect ohmmeter (R x1 scale) between terminals 1 and 2.
3. Connect a 12-volt power supply between terminals 3 and 4. Solenoid should click and
meter should read 0 ohms (full continuity).
4. If meter does not read 0 ohms (full continuity), replace solenoid.
aa

DCV ACV

DVA

33 11

b 44
22
a - 12-VOLT Supply
b - VOA Leads

Page 2B-50 90-859494R1 JUNE 2000


CHARGING & STARTING SYSTEM

Commander 2000 Key Switch Test


1. Disconnect remote control wiring harness and instrument panel connector.
2. Set ohmmeter on R x 1 scale for the following tests.
3. If meter readings are other than specified in the following tests, verify that switch and
not wiring is faulty. If wiring checks ok, replace switch.
IMPORTANT: Key switch must be positioned to “RUN” or “START” and key pushed
in to actuate choke for this test.

KEY CONTINUITY SHOULD BE INDICATED AT THE FOLLOWING POINTS:


POSITION BLK BLK/YEL RED YEL/RED PUR YEL/BLK

OFF

RUN

START

CHOKE*

90-859494R1 JUNE 2000 Page 2B-51

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