Electrical: Section 2B - Charging & Starting System
Electrical: Section 2B - Charging & Starting System
Electrical: Section 2B - 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
Specifications
Special Tools
1. Volt/Ohm Meter 91-99750A1or DMT 2000 Digital Tachometer Multimeter
91-854009A1
a b
54964
4. Protector Cap 91-24161
ÎÎ
ÎÎ
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.
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.
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.
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
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
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
Notes:
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
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
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).
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.
Notes:
13.65
57692
57692
a - Terminal B
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
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)
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.
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.
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
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
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.
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
5
4
12 14
13
9
10
11
23 15
24
16 18
24
25
17
21 19
20
21
22
22 58430
STARTER
TO ALTERNATOR
BATTERY
77
22
11
20 AMP FUSE 66
33
STARTER
SOLENOID
44
55
TEST 1
Use an ohmmeter (Rx1 scale) and connect meter leads
between NEGATIVE (–) battery post and common power-
head ground.
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 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.
*Battery Voltage
TEST 7
a. Connect voltmeter between common engine and Test Point1.
b. Turn ignition key to “Start” position.
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
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
58431
Solenoid Driven Bendix Starter Circuit
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
TEST 2
Use an ohmmeter (Rx1 scale) and connect meter leads
between NEGATIVE (–) battery post and common power-
head ground.
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 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.
TEST 8
a. Connect voltmeter between common engine ground and Test Point 2.
b. Turn ignition key to “Start” position.
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
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
58428
a - Starter Solenoid
b - Mounting Bolts
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
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
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]
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
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
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
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
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)]
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
ed
aa ba c
b dc
51711 11658
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.
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
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
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
bb
aa c
dd
dd
b a 11656
a - POSITIVE (+) Brushes
b - NEGATIVE (–) Brushes
c - Brush Holder
d - Bolts (Fasten NEGATIVE Brushes and Holder)
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)
aa
5″
(127.0 mm)
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
DCV ACV
DVA
33 11
b 44
22
a - 12-VOLT Supply
b - VOA Leads
OFF
RUN
START
CHOKE*