ELECTRICAL

2
B

CHARGING AND STARTING SYSTEM

Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4
Operating Engine Without Battery . . . . . . . . 2B-4
Specific Gravity Readings . . . . . . . . . . . . . . . 2B-4
Specific Gravity Cell Comparison Test . . 2B-5
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . 2B-5
Charging A Discharged Battery . . . . . . . . . . 2B-5
Winter Storage of Batteries . . . . . . . . . . . . . . 2B-6
Battery Charging System Troubleshooting . 2B-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6
Starting System . . . . . . . . . . . . . . . . . . . . . . . . 2B-11
Starting System Components . . . . . . . . . 2B-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . 2B-11
Troubleshooting the Starting Circuit . . . . 2B-11
Starting Circuit Wiring Diagram . . . . . . . . . . . 2B-12
Starting Circuit Troubleshooting Flow Chart 2B-13
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2B-15
Cleaning and Inspection . . . . . . . . . . . . . . 2B-16
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-16
Brush Replacement . . . . . . . . . . . . . . . . . . 2B-18
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . 2B-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-20

2B-0 - ELECTRICAL 90-852572R1 JANUARY 1998

Specifications
Manual Start Recoil Starter
Electric Start
Starter Draw (Under Load) 125 Amperes
STARTING SYSTEM
Recommended Battery Rating
Minimum Reserve Capacity 100 Minutes
Cold Cranking Amperage (CCA) 350 Amperes
Alternator Output
CHARGING SYSTEM Electric Models 16 Amperes @ 2000 RPM
Manual Models 9 Amperes @ 3000 RPM

Special Tools
1. Volt/Ohm Meter 91-99750A1.

90-852572R1 JANUARY 1998 ELECTRICAL - 2B-1

Starter Motor

2 4
5

10
14

8
9
6 7

16 15

12 11 8
14
13

25

25 Liquid Neoprene (92-25711--2)

2B-2 - ELECTRICAL 90-852572R1 JANUARY 1998

 Starter Motor
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 STARTER MOTOR
2 1 THRU BOLT 70 5.8 7.9
3 1 DRIVE KIT
4 1 DRIVE ASSEMBLY
5 1 DRIVE CAP
6 1 ARMATURE
7 1 COMMUTATOR CAP
8 1 BRUSH & SPRING KIT
9 1 BRUSH HOLDER
10 2 SCREW
11 1 LOCKWASHER
12 1 NUT (1/4-20) 60 5 6.8
13 1 BATTERY CABLE (5/16) (POSITIVE)
14 3 SCREW (M8 x 45) 198 16.5 22.3
15 1 DECAL–Warning
16 1 BRACKET-Oil Tank

90-852572R1 JANUARY 1998 ELECTRICAL - 2B-3

Battery Specific Gravity Readings
Use a hydrometer to measure specific gravity of elec-
Precautions trolyte in each cell.

CAUTION
If battery acid comes into contact with skin or
eyes, wash skin immediately with a mild soap.
Flush eyes with water immediately and see a doc- a
tor.
When charging batteries, an explosive gas mixture
forms in each cell. A portion of this gas escapes thru
holes in vent plugs and may form an explosive atmo-
sphere around battery if ventilation is poor. This ex-
plosive gas may remain in or around battery for sev-
eral 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 pre-
vent an explosion.
1. DO NOT smoke near batteries being charged or 22532
which have been charged very recently. a - Hydrometer
2. DO NOT break live circuits at terminals of batter-
ies because a spark usually occurs at the point Hydrometer measures percentage of sulfuric acid in
where a live circuit is broken. Always be careful battery electrolyte in terms of specific gravity. As a
when connecting or disconnecting cable clamps battery drops from a charged to a discharged condi-
on chargers. Poor connections are a common tion, acid leaves the solution and chemically com-
cause of electrical arcs which cause explosions. bines with the plates, causing a decrease in specific
gravity of electrolyte. An indication of concentration
3. DO NOT reverse polarity of battery cables on bat-
of electrolyte is obtained with a hydrometer.
tery terminals.
When using a hydrometer, observe the following
points:
Operating Engine Without 1. Hydrometer must be clean (inside and out) to in-
sure an accurate reading.
Battery 2. Never take hydrometer readings immediately af-
If desired (or in an emergency), engines equipped ter water has been added. Water must be thor-
with an alternator can be started and operated with- oughly mixed with electrolyte by charging for at
out a battery (either disconnected or removed) if least 15 minutes at a rate high enough to cause
“Warning”, below, is followed. vigorous gassing.
3. If hydrometer has built-in thermometer, draw liq-
WARNING uid in several times to ensure correct tempera-
Before operating engine with battery leads dis- ture before taking reading.
connected from battery, disconnect stator leads
4. Hold hydrometer vertically and draw in just
(yellow) from voltage regulator. Insulate (electri-
enough liquid from battery cell so that float is free-
cal tape) stator lead terminals.
floating. Hold hydrometer at eye level so that float
is vertical and free of outer tube, then take read-
ing at surface of liquid. Disregard curvature
where liquid rises against float stem due to capil-
lary action.

2B-4 - ELECTRICAL 90-852572R1 JANUARY 1998

5. Avoid dropping electrolyte on boat or clothing, as Charging A Discharged
it is extremely corrosive. Wash off immediately
with baking soda solution. Battery
Specific gravity of electrolyte varies not only with per- The following basic rules apply to any battery charg-
centage of acid in liquid, but also with temperature. ing situation:
As temperature drops, electrolyte contracts, so that
1. Any battery may be charged at any rate, (in am-
specific gravity increases. Unless these variations in
peres) as long as spilling of electrolyte (from vio-
specific gravity are taken into account, specific grav-
lent gassing) does not occur, and as long as elec-
ity obtained by hydrometer may not give a true indica-
trolyte temperature does not exceed 125° F (52°
tion of concentration of acid in electrolyte.
C). If spewing of electrolyte occurs, or if electro-
A fully charged battery will have a specific gravity lyte temperature exceeds 125° F, charging rate
reading of approximately 1.270 at an electrolyte tem- (in amperes) must be reduced or temporarily
perature of 80° F (27° C). If electrolyte temperature halted to avoid damage to the battery.
is above or below 80° F, additions or subtractions
2. Battery is fully charged when, over a 2-hour peri-
must be made in order to obtain a hydrometer read-
od at a low charging rate (in amperes), all cells
ing corrected to 80° F standard. For every 10° F (3.3°
are gassing freely (not spewing liquid electro-
C) above 80° F, add 4 specific gravity points (.004) to
lyte), and no change in specific gravity occurs.
hydrometer reading. Example: A hydrometer reading
Full charge specific gravity is 1.260-1.275, cor-
of 1.260 at 110° F (43° C) would be 1.272 corrected
rected for electrolyte temperature with electrolyte
to 80° F, indicating a fully charged battery.
level at 3/16” (4.8 mm) over plate. For most satis-
For every 10° below 80° F, subtract 4 points (.004) factory charging, lower charging rates in am-
from the reading. Example: A hydrometer reading of peres are recommended.
1.272 at 0° F (-18° C) would be 1.240 corrected to 80°
3. If, after prolonged charging, specific gravity of at
F, indicating a partially charged battery.
least 1.230 on all cells cannot be reached, battery
is not in optimum condition and will not provide
optimum performance; however, it may continue
Specific Gravity Cell Comparison to provide additional service, if it has performed
Test satisfactorily in the past.
This test may be used when an instrumental tester is 4. To check battery voltage while cranking engine
not available. To perform this test, measure specific with electric starter motor, place red (+) lead of
gravity of each cell, regardless of state of charge, and tester on positive (+) battery terminal and black
interpret results as follows: If specific gravity read- (-) lead of tester on negative (-) battery terminal.
ings show a difference between highest and lowest If the voltage drops below 9-1/2 volts while crank-
cell of .050 (50 points) or more, battery is defective ing, the battery is weak and should be recharged
and should be replaced. or replaced.

Electrolyte Level
Check electrolyte level in battery regularly. A battery
in use in hot weather should be checked more fre-
quently because of more rapid loss of water. If elec-
trolyte level is found to be low, then distilled water
should be added to each cell until liquid level rises ap-
proximately 3/16” (4.8mm) over plate. DO NOT
OVERFILL, because this will cause loss of electro-
lyte and result in poor performance, short life and ex-
cessive corrosion.

CAUTION
During service, only distilled water should be
added to the battery, not electrolyte.

90-852572R1 JANUARY 1998 ELECTRICAL - 2B-5

Winter Storage of Batteries Battery Charging System
Battery companies are not responsible for battery Troubleshooting
damage, either in winter storage or in dealer stock,
if the following instructions are not observed: Description
1. Remove battery from its installation as soon as The battery charging system components are the
possible and remove all grease, sulfate and dirt stator, voltage regulator/rectifier and the battery.
from top surface by running water over top of bat- Alternating current is generated in the stator alterna-
tery. Be sure, however, that vent caps are tight tor coils and flows to the regulator/rectifier. The recti-
beforehand, and blow off all excess water thor- fier changes the alternating current to direct current
oughly with compressed air. Check water level, for charging the battery and the regulator senses bat-
making sure that plates are covered. tery voltage and allows the correct amount of direct
2. When adding distilled water to battery, be ex- current to charge the battery.
tremely careful not to fill more than 3/16” (4.8mm) The charging system may be damaged by:
over plate inside battery. Battery solution or elec-
trolyte expands from heat caused by charging. a. Reversed battery cables.
Overfilling battery will cause electrolyte to over- b. Running the engine with battery cables dis-
flow (if filled beyond 3/16” (4.8 mm) over plate). connected and stator leads connected to reg-
3. Grease terminal bolts well with Quicksilver 2-4-C ulator/rectifier.
Marine Lubricant, and store battery in COOL- c. Open circuit, such as a broken wire or loose
DRY place. Remove battery from storage every connection.
30-45 days, check water level (add water if nec-
essary), 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 bat-
tery for reason, and then recharge. When gravity
reaches 1.260, discontinue charging. To check a
specific gravity, use a hydrometer, which can be
purchased locally.
5. Repeat preceding charging procedure every
30-45 days, as long as battery is in storage.
When ready to place battery back in service, re- b d
move excess grease from terminals (a small
amount is desirable on terminals at all times), re-
charge again as necessary and re-install battery.

WARNING c
Hydrogen and oxygen gases are produced dur-
ing normal battery operation or charging. Sparks a - Stator
b - Voltage Regulator/Rectifier
or flame can cause this mixture to ignite and ex-
c - Start Solenoid
plode if they are brought near the battery. Sulfu- d - 12V Battery
ric acid in battery can cause serious burns, if
spilled on skin or in eyes. Flush or wash away im- A fault in the battery charging system usually will
mediately with clear water. cause the battery to become undercharged. Check
battery electrolyte level, and charge battery. See
“Electrolyte Level”, and “Charging a Discharged Bat-
tery”.
If battery will not accept a satisfactory charge, re-
place battery.
If battery accepts a satisfactory charge, determine
the cause of the charging system problem as follows.

2B-6 - ELECTRICAL 90-852572R1 JANUARY 1998

1. Check for correct battery polarity [red cable to STATOR OHMS TEST
positive (+) battery terminal]. If polarity was incor- (ALTERNATOR COILS ONLY)
rect, check for damaged rectifier. See “rectifier
NOTE: Stator can be tested without removing from
test”, later in this section.
engine.
2. Check for loose or corroded battery connections.
1. Disconnect both yellow (stator leads) from volt-
3. Visually inspect wiring between stator and bat- age regulator/rectifier, or terminal block.
tery for cuts, chafing, and disconnected, loose or
2. Use an ohmmeter and perform the following test.
corroded connection.
IMPORTANT: If stator is mounted on engine, black
4. Excessive electrical load (from too many acces-
stator lead (if provided) must be grounded to power-
sories) will cause battery to run down.
head when testing.
If visual inspection determines that battery connec-
3. Replace stator if readings are outside ranges
tions and wiring are OK, perform the following stator
shown.
and alternator systems tests.
NOTE: Resistance varies greatly with temperature.
Measurements should be taken with an ambient tem-
perature range of 65° to 85° F.

9 Ampere Manual Stator

Resistance Scale
Test Leads
(Ohms) Reading
Between Yellow
0.16 - 0.19* Rx1
Stator Leads
Between Either
Yellow Stator Lead
No Continuity R x 1000
and Engine
Ground
* DC Resistance of these windings generally is less than
1.5 Ohms. If a reading resembling a short is obtained, this
would be acceptable.

16 Ampere Stator
Resistance Scale
Test Leads
(Ohms) Reading
Between Yellow
0.16 - 0.19* Rx1
Stator Leads
Between Either
Yellow Stator Lead
No Continuity R x 1000
and Engine
Ground
* DC Resistance of these windings generally is less than
1.5 Ohms. If a reading resembling a short is obtained, this
would be acceptable.

90-852572R1 JANUARY 1998 ELECTRICAL - 2B-7

ALTERNATOR SYSTEMS TEST 6. Remove RED sense lead wire from starter sole-
noid terminal and connect to the positive (+) ter-
9 Ampere Manual Stator
minal of a 9 volt transistor battery. Ground the
IMPORTANT: Rectifier (optional accessory) must negative (–) terminal of the 9 volt battery to the
be functioning properly for accurate test results engine.
to be obtained.
1. Remove RED lead from (+) terminal of rectifier.
2. Connect RED (+) ammeter lead to rectifier (+) ter-
a
minal and BLACK (–) ammeter lead to RED recti-
fier lead.
3. With engine running at the indicated RPM, the
ammeter should indicate the following approxi-
mate amperes: a - Red Sense Lead (Female Connector)

RPM AMPERES
Idle 0 7. Connect RED (+) ammeter lead to larger diame-
9 Ampere ter RED harness wire, and BLACK (–) ammeter
Manual Stator 1000 0.6
lead to POSITIVE terminal on starter solenoid.
2000 8.0
8. Secure starter wires away from flywheel.
3000 9.0
9. With engine running at the indicated RPM’s, the
4. If proper ampere readings are not obtained, re- ammeter should indicate the following approxi-
place stator. mate amperes:
RPM AMPERES
16 Ampere Idle 2.8
16 Ampere Stator
S
Stator 1000 9.3
1. Check battery voltage at battery with engine run-
ning. 2000 16
2. If battery voltage is above 14.5 volts, replace volt- 10. A reading of 16 amperes at 2000 RPM indicates
age regulator/rectifier. Check condition of battery the charging system is functioning properly. The
as overcharging may damage battery. battery is being discharged because of the
3. If battery voltage is below 14.5 volts, charge bat- excessive amperage draw on the system (the
tery; refer to “Charging a Discharged Battery”, draw is greater than the amperage output of the
preceding. If battery can not be satisfactorily engine charging system).
charged, replace battery. 11. If ammeter reads less than required amperes @
4. If battery accepts a satisfactory charge, check 3000 RPM, test the stator; refer to “Stator Ohm
battery voltage while cranking engine; refer to Test (Alternator Coils Only)”. If stator tests OK,
“Charging a Discharged Battery”, preceding. If replace voltage regulator.
cranking voltage is not acceptable, replace battery.
5. If cranking voltage is acceptable, disconnect
larger diameter RED harness wire from starter
solenoid terminal.

2B-8 - ELECTRICAL 90-852572R1 JANUARY 1998

RECTIFIER TEST (OPTIONAL ACCESSORY
FOR 9 AMP STATOR) d
a c
WARNING
Disconnect battery leads from battery before
testing rectifier.
b
NOTE: Rectifier can be tested without removing from
engine. f
1. Disconnect all wires from terminals on rectifier.
2. Use an ohmmeter (R x 1000 scale) and perform
the following test. Refer to drawing for rectifier e
terminal identification.

07300
a - Terminal
b - Terminal
c - Terminal
d - Stator Terminals
e - Positive Terminal
f - Ground

Connect red meter lead to ground, black lead alternately

to terminals “a” and “c”.

Continuity Indicated. No Continuity Indicated.

Connect black meter lead to ground, red lead Connect black meter lead to ground, red lead
alternately to terminals “a” and “c”. alternately to terminals “a” and “c”.

No Continuity Indicated. Continuity Indicated.

Connect black meter lead to terminal “b”, red Replace Rectifier.
lead alternately to terminals “a” and “c”.

No Continuity Indicated. Continuity Indicated.

Replace Rectifier. Connect black meter lead to terminal “b”, red
lead alternately to terminals “a” and “c”.

Continuity Indicated. No Continuity Indicated.

Connect red meter lead to terminal “b”, Replace Rectifier.
black lead alternately to terminals “a”
and “c”.

Continuity Indicated. No Continuity Indicated

Replace Rectifier. Connect red meter lead to terminal “b”,
black lead alternately to terminals “a”
and “c”.

No Continuity Indicated. Continuity Indicated. No Continuity Indicated. Continuity Indicated.

Rectifier tests O.K. Replace Rectifier. Replace Rectifier. Rectifier Tests O.K.

90-852572R1 JANUARY 1998 ELECTRICAL - 2B-9

VOLTAGE REGULATOR/RECTIFIER TEST SCR TEST:
NOTE: Voltage regulator/rectifier specifications are 1. Set Ohm meter to R X 1k scale.
given for informational purposes only, use the
2. Connect Red (+) meter lead to regulator case.
appropriate troubleshooting techniques previously
mentioned to find the faulty component in the charg- 3. Connect Black (–) meter lead to one YELLOW
ing system. regulator lead. Test. Connect Black (–) meter
lead to the other YELLOW lead.
TEST RESULTS (BOTH TESTS):
15,000 -  OHMS (15k - )

TACHOMETER CIRCUIT TEST:

1. Set Ohm meter to R X 1k scale.
2. Connect Red (+) meter lead to GREY regulator
lead.
DIODE TEST:
3. Connect Black (–) meter lead to regulator case.
1. Set Ohm meter to R X 10 scale.
TEST RESULTS:
2. Connect Red (+) meter lead to RED regulator 10,000 - 50,000 OHMS (10k - 50k)
lead.
3. Connect Black (–) meter lead to YELLOW regula-
tor lead.
TEST RESULTS:
100 - 400 OHMS

DIODE TEST:
1. Set Ohm meter to R X 1k scale.
2. Connect Black (–) meter lead to RED regulator
lead.
3. Connect Red (+) meter lead to YELLOW regula-
tor lead. Test. Then change Red (+) meter lead to
the other YELLOW regulator lead for 2ND test
reading.
TEST RESULTS (1ST READING):
40,000 to  OHMS
TEST RESULTS (2ND READING):
 OHMS (No needle movement)

2B-10 - ELECTRICAL 90-852572R1 JANUARY 1998

Starting System Troubleshooting the Starting Circuit
Before beginning the starting circuit troubleshooting
flow chart, following, check first for the following con-
Starting System Components ditions:
The starting system consists of the following compo- 1. Make sure that battery is fully charged.
nents.
2. Check that control lever is in “NEUTRAL” posi-
1. Battery tion.
2. Starter Solenoid 3. Check bullet connectors for corrosion and loose
3. Neutral Start Switch connections.

4. Starter Motor 4. Check cables and wiring for frayed and worn in-
sulation.
5. Ignition Switch
5. Check in-line fuse in RED wire; see diagram.

Description
The function of the starting system is to crank the en-
gine. The battery supplies electrical energy to crank
the starter motor. When the ignition switch is turned
to “START” position, the starter solenoid is activated
and completes the starting circuit between the bat-
tery and starter.
The neutral start switch opens the start circuit when
the shift control lever is not in neutral. This prevents
accidental starting when 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.

90-852572R1 JANUARY 1998 ELECTRICAL - 2B-11

Starting Circuit Wiring Diagram

b
a 4
5

f c

2
3 d

6
1
a - Key Switch
b - Neutral Start Switch
c - Starter
d - Solenoid
e - Battery
f - 20 Amp Fuse

2B-12 - ELECTRICAL 90-852572R1 JANUARY 1998

Starting Circuit Troubleshooting Flow Chart
Starter Motor Does Not Turn

SAFETY WARNING: Disconnect BLACK (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 (R x 1 scale) and connect meter leads be-
tween NEGATIVE (-) battery post and common powerhead
ground.

No continuity indicated; there is an open circuit in the BLACK Continuity Indicated

NEGATIVE (-) battery cable between the NEGATIVE (-) battery Proceed to TEST 2
post and the powerhead.
• Check cable for loose or corroded connections.
• Check cable for open circuit.
* Battery Voltage

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

TEST 3 12 Volt Reading*

a. Reconnect BLACK ground wire(s). 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
c. Turn ignition key to “Start” position. solenoid; proceed to TEST 7.

No voltage reading; 12 Volt Reading

proceed to TEST 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; b. Turn ignition key to “Start” position. wire is open between Test Points 4 and 3.
proceed to TEST 5.

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
Connect voltmeter between common engine ground and Test Point 6.

No voltage reading; check RED wire between 12 Volt Reading*

battery (+) positive terminal and Test Point 6. Check fuse in RED wire between test points 5 and 6.
Check for open RED wire between test points 5 and 6.

90-852572R1 JANUARY 1998 ELECTRICAL - 2B-13

 TEST 7
a. Connect voltmeter between common engine ground and Test Point 1.
b. Turn ignition key to “Start” position.

No voltage reading; De- 12 Volt Reading*

fective starter solenoid. Should hear solenoid click; proceed to TEST 8.

TEST 8
a. Reconnect BLACK (starter motor) cable 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 12 Volt Reading*

for poor connection or open circuit. Check BLACK ground cable at starter for
loose or corroded connection, or open circuit.
If cable is O.K., check starter motor.

2B-14 - ELECTRICAL 90-852572R1 JANUARY 1998

 a
Starter Motor c

Removal

WARNING
Always disconnect the battery and remove spark
plug leads from spark plugs before working on
motor. a c
b
1. Disconnect battery leads from battery.
a - Thru Bolts
2. Disconnect BLACK cable (w/YELLOW sleeve). b - Commutator End Cap
c - Brush/Springs
3. Remove 3 bolts.
4. Remove starter.
2. Pull armature from starter frame.
3. Remove locknut.

b
b

a a
b
55329

a - Black Cable (w/YELLOW sleeve)

b - Bolts (3)
a - Armature
b - Locknut
Disassembly
1. Remove 2 thru bolts and commutator end cap,
taking care not to lose brush springs.

90-852572R1 JANUARY 1998 ELECTRICAL - 2B-15

4. Remove components from armature. b. Clean the commutator slots after undercut-
ting.
d
c. De-burr the commutator lightly with No. 00
e f sandpaper, then clean the commutator.
d. Check the armature on a growler for shorts.
See “Testing”, following.
9. Open-circuited armatures are repairable. The
most likely place for an open circuit is at the com-
mutator bars. Long cranking periods overheat
the starter motor so that solder in the connections
melts. The poor connections cause arcing and
a c burning of the commutator bars.
b
10. Repair bars, that are not too badly burned, by re-
soldering the leads in bars (using rosin flux sol-
der) and turning down the commutator in a lathe
to remove burned material, then undercut the
a - Spacer mica.
b - Spring
11. Clean out the copper or brush dust from slots be-
c - Drive Assembly
d - Drive End Cap tween the commutator bars.
e - Armature Shaft 12. Check the armature for shorts and ground. See
f - Washer “Testing”, following.

Cleaning and Inspection

Testing
1. Clean all motor parts.
2. Check pinion teeth for chips, cracks or excessive ARMATURE TEST FOR SHORTS
wear. Check armature for short circuits by placing on growl-
3. Replace the drive clutch spring and/or collar, if er and holding hack saw blade over armature core
tension is not adequate, or if wear is excessive. while armature is rotated. If saw blade vibrates, ar-
mature is shorted. Re-check after cleaning between
4. Check that the brush holder is not damaged or is commutator bars. If saw blade still vibrates, replace
not holding the brushes against the commutator. armature.
5. Replace brushes that are pitted or worn to less
than 1/4 in. (6.4mm) in length. Refer to “Brush
Replacement”, following.
6. Replace a damaged or excessively worn bushing
in the end cap.
7. Check the armature conductor (commutator bar
junction) for a firm connection. A poor connection
usually results in a burned commutator bar.
8. Re-surface and undercut a rough commutator, as
follows:

CAUTION
Do not turn down the commutator excessively.
a. Re-surface the commutator and undercut the
insulation between the commutator bars 1/3
in. (8.5 mm) to the full width of the insulation,
make sure that the undercut is flat.

2B-16 - ELECTRICAL 90-852572R1 JANUARY 1998

ARMATURE TEST FOR GROUND TESTING NEGATIVE BRUSHES FOR GROUND
1. Set ohmmeter to (R x 1 scale). Place one lead of Set ohmmeter to (R x 1 scale). Place one lead of
ohmmeter on armature core (or shaft) and other ohmmeter on the negative brush and the other lead
lead on commutator, as shown. on the end cap (bare metal). If the meter indicates no
continuity, replace the negative brush. Repeat this
2. If meter indicates continuity, armature is
procedure on the other negative brush.
grounded and must be replaced.

a b

11675

CHECKING POSITIVE BRUSHES AND TERMI-

NALS
1. Connect ohmmeter (R x 1 scale) leads between
positive brushes. a - Negative (-) Brushes
b - End Cap
2. Ohmmeter must indicate full continuity (zero re-
sistance). If resistance is indicated, check lead to
positive terminal solder connection. If connection
cannot be repaired, brushes must be replaced.
Refer to “BRUSH REPLACEMENT”.

11673

a - Positive Brushes

90-852572R1 JANUARY 1998 ELECTRICAL - 2B-17

STARTER SOLENOID TEST Brush Replacement
Test starter solenoid as follows: IMPORTANT: Replace brushes that are pitted or
1. Disconnect all leads from solenoid terminals. worn to less than 1/4 in. (6.4 mm) in length.
2. Use an ohmmeter, set to (R x 1 scale) and con-
nect between solenoid terminals 3 and 4.
3. Connect a 12-volt supply between solenoid ter-
minals 1 and 2. Solenoid should click and meter
should read zero ohms. c
4. If meter does not read zero ohms (full continuity),
replace solenoid.

e b a

f
g
11660

a - Positive (+) Terminal

b - Long Brush Lead
c - Push Lead Into Slot
d - Insulating Washer
e - Flat Washer
f - Lock Washer
g - Nut
4 1
a b
c

a
b

3 2
14354
a - Ohmmeter Leads d
d
b - 12-Volt Supply

b a

11656

a - Positive (+) Brushes

b - Negative (–) Brushes
c - Brush Holder
d - Bolts (Fasten Negative Brushes and Holder)

2B-18 - ELECTRICAL 90-852572R1 JANUARY 1998

Reassembly Brush Retainer Tool Layout (Full Size)

1. Lubricate helix threads and drive end cap bush-

ing with SAE 10W oil.
2. Install components onto armature shaft.

b a
c

e
g
f

11658

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

3. Install locknut.
a

Brush Retainer Tool Side View (Full Size)

18-Gauge Sheet Metal

METRIC
SCALE
3” = 76.2mm
2” = 50.8mm
1-3/4” = 44.5mm
1-11/16”= 42.9mm
3/4” = 19.1mm
51711 1/2” = 12.7mm

4. Construct a brush retainer tool as shown.

90-852572R1 JANUARY 1998 ELECTRICAL - 2B-19

5. Place springs and brushes into brush holder and Installation
hold in place with brush retainer tool.
1. Secure starter to block with 3 bolts. Torque bolts
6. Lubricate bushing with one drop of SAE 10W oil. to 16.6 lb. ft. (22.5 N·m). Secure NEGATIVE bat-
DO NOT over-lubricate. tery lead to block with bottom bolt.
2. Connect battery lead (BLACK w/YELLOW
a sleeve) to starter. Torque attaching nut to 60 lb.
in.(6.8 N·m).

11661
a - Brush Retainer Tool
b - Bushing

7. Position armature into starter frame so that com-

mutator end of armature is at end of starter frame a
b
where permanent magnets are recessed 1 in.
(25.4 mm). Align marks as shown. 55329
8. Install commutator end cap onto starter frame;
align marks as shown, and remove brush retainer a - Black Cable (w/YELLOW sleeve)
tool. b - Bolts (3)

9. Install thru bolts and torque to 70 lb. in. (7.9 N·m).

c c

52659
a - Alignment Marks
b - End Cap Alignment Marks
c - Bolts

2B-20 - ELECTRICAL 90-852572R1 JANUARY 1998