CHARGING & STARTING SYSTEM

ELECTRICAL
Section 2B - Charging & Starting System
Table of Contents
2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Flywheel Removal/Installation . . . . . . . . . . . . . 2B-18
B
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-18
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-20
Electrical Components . . . . . . . . . . . . . . . . . . . 2B-6 Stator Removal/Installation . . . . . . . . . . . . . . . 2B-21
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-10 Voltage Regulator/Rectifier
Battery Charging System . . . . . . . . . . . . . . . . . 2B-11 Removal/Installation . . . . . . . . . . . . . . . . . . . . 2B-22
Description (20 Ampere) . . . . . . . . . . . . . . 2B-11 Starting System Components . . . . . . . . . . . . . 2B-23
Wiring Diagram (20 Ampere) . . . . . . . . . . . 2B-11 Description . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-23
Charging System Description . . . . . . . . . . . . . 2B-12 Troubleshooting the Starting Circuit . . . . . . . . 2B-23
Flywheel Assembly . . . . . . . . . . . . . . . . . . . 2B-12 Starter Solenoid Test . . . . . . . . . . . . . . . . . . 2B-24
Stator Assembly . . . . . . . . . . . . . . . . . . . . . . 2B-12 Starter Motor Servicing . . . . . . . . . . . . . . . . . . . 2B-27
Voltage Regulator/Rectifier Assembly . . . 2B-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-27
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-13 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-27
Battery Charging System Troubleshooting . . 2B-13 Cleaning and Inspection . . . . . . . . . . . . . . . 2B-29
Alternator System Test . . . . . . . . . . . . . . . . 2B-14 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-30
Stator Resistance Test - 20 Amp. Stator . 2B-15 Brush Replacement . . . . . . . . . . . . . . . . . . . 2B-32
Suppression Diode Tests . . . . . . . . . . . . . . 2B-15 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-33
Regulator/Rectifier (P/N 854514-1) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-36
Diode Test . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-16

Specifications
Alternator Type: Single Phase (12 Pole)
CHARGING
20 Amp. Electric Alternator Output 12.6 V-20 Amps. (252 Watts)
SYSTEM
(Rectified/Regulated)
Readings taken @
Stator Resistance 0.20 - 0.30 Ohms (YEL-YEL)
68°F (20°C).
Quicksilver Tachometer Setting “6P” or “4”
Electric Start:
Starter Type Bendix
STARTING Output 1.1 kW
SYSTEM Ampere Draw Under:
(Load) 174.0 Amps
(No Load) 23.7 Amps
Battery Rating
Minimum Requirement 465 Marine Cranking Amps (MCA)
or 350 Cold Cranking Amps (CCA)
For operation below 32° F (0° C) 1000 Marine Cranking Amps (MCA) or
BATTERY 775 Cold Cranking Amps (CCA)
Ampere-Hours (Ah) Minimum
For operation above 32° F (0° C) 70
For operation below 32° F (0° C) 105

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CHARGING & STARTING SYSTEM

Special Tools
1. Flywheel Holder P/N 91-83163M

2. Flywheel Puller P/N 91-83164M

3. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1

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 CHARGING & STARTING SYSTEM

Notes:

90-883065 APRIL 2001 Page 2B-3

CHARGING & STARTING SYSTEM

FLYWHEEL
2 3

6
110

7 9 8
10

15
4
16

19

11

13
5
14

12

17
18

20

110 4-Stroke Outboard Oil (92-828000A12)

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 CHARGING & STARTING SYSTEM

FLYWHEEL
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 FLYWHEEL COVER
2 4 SCREW (M6 X 25) 75 8.5
3 1 DECAL - EPA INFORMATION (SEE NOTE)
4 1 FLYWHEEL
5 1 DRIVEN GEAR
6 1 DECAL - WARNING SPINNING FLYWHEEL
7 1 DECAL - TIMING MARKS
8 1 DECAL - WARNING-NEUTRAL
9 1 NUT 115 155.9
10 1 WASHER
11 3 SCREW (M5 X 30) 85 9.6
12 1 STATOR
13 1 LOAD RING
14 1 DRIVE GEAR
15 1 SCREW (M10 X 40) 28 38
16 1 WASHER
17 1 KEY
18 1 KEY
19 1 TIMING BELT
20 1 STA-STRAP
NOTE: THE EPA LABEL HAS IMPORTANT INFORMATION REGARDING EPA EMISSION
REGULATIONS. REPLACE ANY MISSING OR UNREADABLE EPA LABEL.

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CHARGING & STARTING SYSTEM

ELECTRICAL COMPONENTS
6 Dielectric Grease (92-823506--1) 44

9 Loctite PST Pipe Sealant (92-809822) 13

25 Liquid Neoprene (92-25711--3)
66 Loctite 242 (92-809821)
66 11
12
9 10
14
8
5 6

7 15
4 66
12
2 3 6
4 16 25
15
27
1
18
3 17
4
1 25
3
1 21
24 20
26 19
24
29
30 23
6 21

22
43
31
35 28 25
42
41 33
32
34
25 24
38
36
45

37
39 40

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 CHARGING & STARTING SYSTEM

ELECTRICAL COMPONENTS
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 3 SCREW (M6 X 25) 45 5.1
2 1 PLATE
3 3 WASHER
4 3 GROMMET
1 ECM (50)
5 1 ECM (60)
3 ECM (40)
6 3 BUSHING
7 2 SCREW 45 5.1
8 1 BRACKET
9 1 RETAINER
10 1 RETAINER
11 1 PLATE
12 3 SCREW (M6 X 16) 75 8.5
13 1 J CLAMP
14 1 BRACE
15 2 SCREW (M6 X 14) 45 5.1
16 1 SOLENOID PLATE
17 1 SCREW (M6 X 14) 45 5.1
18 1 BRACKET
19 1 SOLENOID
20 1 CABLE
21 2 NUT 60 6.8
22 1 BATTERY CABLE (POSITIVE)
23 1 BOOT (RED)
24 1 ENGINE WIRING HARNESS
4 FUSE (20 AMP)
25
1 FUSE (15 AMP)
26 1 COVER
27 1 DIODE ADAPTOR CABLE
28 1 PLUG (MALE)
29 1 CRANK POSITION SENSOR
30 2 SCREW (M5 X 16) 45 5.1
31 1 VOLTAGE REGULATOR
32 1 BRACKET
33 1 FOAM PAD
34 2 SCREW (M6 X 40) 75 8.5
35 1 PRESSURE SWITCH 75 8.5
36 1 STARTER MOTOR (SEE BREAKDOWN ON STARTER MOTOR)
37 1 NUT (1/4-20) 60 6.8
38 1 BATTERY CABLE (NEGATIVE)
39 1 J CLIP

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CHARGING & STARTING SYSTEM

ELECTRICAL COMPONENTS

6 Dielectric Grease (92-823506--1) 44

9 Loctite PST Pipe Sealant (92-809822) 13

25 Liquid Neoprene (92-25711--3)
66 Loctite 242 (92-809821)
66 11
12
9 10
14
8
5 6

7 15
4 66
12
2 3 6
4 16 25
15
27
1
18
3 17
4
1 25
3
1 21
24 20
26 19
24
29
30 23
6 21

22
43
31
35 28 25
42
41 33
32
34
25 24
38
36
45

37
39 40

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 CHARGING & STARTING SYSTEM

ELECTRICAL COMPONENTS
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
40 3 SCREW (M8 X 45) 21.7 29.4
41 2 SCREW (M6 X 25) 75 8.5
42 AR STA-STRAP
43 4 SPARK PLUG (RA8HC) 20 21.1
44 1 SCREW (M5 X 12) 45 5.1
45 1 EXTENSION HARNESS (HANDLE)

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CHARGING & STARTING SYSTEM

STARTER MOTOR

2
3

1 6

11
10

9
4 7

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 STARTER MOTOR
2 2 THRU BOLT 70 8.0
3 1 DRIVE KIT
4 1 ARMATURE
5 1 PINION
6 1 DRIVE CAP
7 1 COMMUTATOR CAP
8 1 BRUSH & SPRING KIT
9 1 BRUSH HOLDER
10 2 SCREW
11 1 DECAL-Warning-High voltage

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 CHARGING & STARTING SYSTEM

Battery Charging System

Description (20 Ampere)
The battery charging system components are the flywheel, stator, regulator/rectifier, and
battery. Alternating current (generated in battery charge coils) flows to the regulator/rectifier,
which changes the alternating current to a regulated direct current for charging the battery.
Wiring Diagram (20 Ampere)
BLK = Black
RED = Red
GRY = Gray
YEL = Yellow
a

YEL YEL b
e

RED

GRY RED
d
YEL BLK
RED

YEL
BLK
RED
f
c
a - Stator
b - Voltage Regulator/Rectifier
c - Connector
d - To Engine Ground
e - To Battery Positive (Red) Terminal
f - To Battery Negative (Black) Terminal

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CHARGING & STARTING SYSTEM

Charging System Description

Flywheel Assembly

The flywheel assembly contains six permanently charged magnet segments which are
bonded and retained to the inner wall of the flywheel. Each magnet contains a north and a
south pole providing a 12 pole system.

Stator Assembly

58489

The stator assembly located under the flywheel contains the battery charge coils. As the
flywheel permanent magnets pass the respective stator coil windings, an AC pulse current
is produced at each coil winding when magnet polarity changes. (South to North), (North
to South) etc.

Voltage Regulator/Rectifier Assembly

The voltage regulator converts the alternating current from the stator to direct current that
can be stored in the battery.

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 CHARGING & STARTING SYSTEM

Battery

A 12 volt battery with a minimum rating of 465 marine cranking amps (MCA) or 350 cold
cranking amps (CCA). For operation below 32° F (0° C) a rating of 1000 Marine Cranking
Amps (MCA) or 775 Cold Cranking Amps (CCA) is recommended.

Battery Charging System Troubleshooting

CAUTION
The charging system may be damaged by: 1) reversed battery cables, 2) an open
circuit, such as a broken wire or loose connection.
A fault in the battery charging system usually will cause the battery to become under-
charged. Check battery electrolyte level, and charge battery.
If battery will NOT accept a satisfactory charge, replace battery.
If battery accepts a satisfactory charge, determine the cause of the charging system prob-
lem as follows.
1. Check for correct battery polarity [RED cable to POSITIVE (+) battery terminal]. If polar-
ity was incorrect, check for damaged regulator/rectifier. See “REGULATOR/RECTIFI-
ER DIODE TEST”.
2. Check for loose or corroded battery connections.
3. Visually inspect wiring between stator and battery for cuts, chafing, and a disconnected,
loose or corroded connection.
4. Excessive electrical load (from too many accessories) will cause battery to run down.
If visual inspection determines that battery connections and wiring are OK, perform the fol-
lowing stator and regulator/rectifier tests.

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CHARGING & STARTING SYSTEM

Alternator System Test

20 AMPERE STATOR
1. Check battery voltage at battery with engine running.
2. If battery voltage is above 15.0 volts, replace voltage regulator/rectifier. Check condition
of battery as overcharging may have damaged battery.
3. If battery voltage is below 12.5 volts, charge battery. If battery can NOT be satisfactorily
charged, replace battery.
4. If battery accepts a satisfactory charge, check battery voltage while cranking engine. If
cranking voltage is not acceptable, replace battery.
5. If cranking voltage is acceptable, disconnect the RED (voltage regulator) connector.
6. Connect RED (+) ammeter lead to RED voltage regulator wire, and the BLACK (–) am-
meter lead to the RED wiring harness wire.
7. Secure stator wires away from flywheel.
8. With engine running at the indicated RPM’s, the ammeter should indicate the following
appropriate amperes:
20

18

16
Alternator current (Amps)

14

12

10

0
0 1 2 3 4 5 6
RPM x 1000

9. A reading of 19.5 amperes at 5000 RPM indicates the charging system is functioning
properly.
10. If ammeter reads less than required amperes @ 5000 RPM, test the stator (refer to “Sta-
tor Resistance Test”). If stator tests OK, replace rectifier/regulator.

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 CHARGING & STARTING SYSTEM

Stator Resistance Test - 20 Amp. Stator

METER READING
METER TEST LEADS SCALE (

(ANALOG)
RED BLACK
YEL YEL RX1 0 20 - 0
0.20 0.30
30

NOTE: If using DMT 2000 turn the selector switch to
. Allow the meter to auto-range.
Suppression Diode Tests
The suppression diode is located between the brown start solenoid lead, the yellow/red key
switch lead (within the engine harness) and connects to engine ground. The purpose of the
suppression diode is to eliminate the inductive spike created as the start solenoid is de-ener-
gized (key switch turned from START to RUN).
Symptoms of a failed suppression diode:
1. Open circuit - Longer crank times during engine start-up (3 seconds warm engine).
2. Short circuit - Blown fuse #3 (Main Power Relay/Accessory).

BLK

BRN YEL/RED

DIODE TEST
BLK RED YEL/RED BRN BLK
YEL/RED X 0V or SHORT 0.4 - 0.8V
BRN 0V or SHORT X 0.4 - 0.8V
BLK OUCH, OL, ∞ OUCH, OL, ∞ X

RESISTANCE TEST
BLK RED YEL/RED BRN BLK
YEL/RED X < 0.5 1 - 3M

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CHARGING & STARTING SYSTEM

BRN < 0.5 X 1 - 3M

BLK OUCH, OL, ∞ OUCH, OL, ∞ X

Regulator/Rectifier (P/N 854514-1) Diode Test

ANALOG METER
NOTE: Voltage regulator/rectifier specifications are given for informational purposes only.
Use the appropriate troubleshooting techniques previously mentioned to find the faulty
component in the charging system.
BLK = Black
GRY = Gray
RED = Red
BLK YEL = Yellow

GRY
YEL

YEL

RED

DIODE TEST:
1. Set Ohm meter to R X 10 scale.
2. Connect Red (+) meter lead to RED regulator lead.
3. Connect Black (–) meter lead to either YELLOW regulator 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 regulator lead. Test. Then change Red (+) me-
ter lead to the other YELLOW regulator lead for 2ND test reading.
TEST RESULTS (1ST READING):
20,000 to ∞ OHMS
TEST RESULTS (2ND READING):
∞ OHMS (No needle movement)
SCR TEST:
1. Set Ohm meter to R X 1k scale.
2. Connect Red (+) meter lead to regulator case.
3. Connect Black (–) meter lead to one YELLOW regulator lead. Test. Connect Black (–)
meter lead to the other YELLOW lead.
TEST RESULTS (BOTH TESTS):
8,000 - 15,000 OHMS (8k - 15K)

Page 2B-16 90-883065 APRIL 2001

 CHARGING & STARTING SYSTEM

TACHOMETER CIRCUIT TEST:

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

DIGITAL METER
NOTE: Voltage regulator/rectifier specifications are given for informational purposes only.
Use the appropriate troubleshooting techniques previously mentioned to find the faulty
component in the charging system.
BLK = Black
BLK GRY = Gray
RED = Red
YEL = Yellow
GRY
YEL

YEL

RED

DIODE TEST:
1. Set meter to .
2. Connect Black (–) meter lead to RED regulator lead.
3. Connect Red (+) meter lead to either YELLOW regulator lead.
TEST RESULTS:
0.4-0.8 V
DIODE TEST:
1. Set meter to .
2. Connect Red (+) meter lead to RED regulator lead.
3. Connect Black (–) meter lead to either YELLOW regulator lead.
TEST RESULTS (1ST READING):
∞ or OUCH or OL
SCR TEST:
1. Set meter to .
2. Connect Black (–) meter lead to regulator case.
3. Connect Red (+) meter lead to either YELLOW regulator lead.
TEST RESULTS (BOTH TESTS):
1.5 V - ∞ or OUCH or OL

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CHARGING & STARTING SYSTEM

Flywheel Removal/Installation
WARNING
Engine could possibly start when turning flywheel during removal and installation.
To prevent this type of accidental engine starting and possible serious injury, al-
ways remove spark plug leads from spark plugs.
Removal
1. Remove flywheel cover.

a - Flywheel Cover
b - Screw (4) M6 x 25

Page 2B-18 90-883065 APRIL 2001

 CHARGING & STARTING SYSTEM

2. Loosen flywheel nut. Hold flywheel using flywheel holder (91-83163M).

3. Remove nut and washer.
NOTE: Removal of the nut may require the use of an impact tool.

c
d
91-83163M

a - Flywheel Holder (91-83163M)

b - Breaker Bar with 30 mm Socket
c - Nut
d - Washer
4. Loosen flywheel using puller (91-83164M). Remove flywheel and key.
NOTE: Apply a small amount of grease to the end of the crankshaft before installing puller.

c
b

91-83164M

58815 58227

a - Flywheel Puller (91-83164M)

b - Flywheel
c - Key

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CHARGING & STARTING SYSTEM

Installation
1. Place flywheel key into slot.
2. Install flywheel. Apply oil to threads on crankshaft.
3. Install washer and nut.
4. Hold flywheel using flywheel holder (91-83163M) and tighten nut to the specified torque.
d
110
c

a
b
91-83163M

58227

110 4-Stroke Outboard Oil (92-828000A12)

a - Key
b - Flywheel
c - Washer
d - Nut
e - Torque Wrench with 30mm socket
f - Flywheel Holder (91-83163M)

Flywheel Nut Torque

115 lb. ft. (155.9 N·m)

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 CHARGING & STARTING SYSTEM

Stator Removal/Installation
NOTE: Remove flywheel as outlined in “Flywheel Removal and Installation” section of ser-
vice manual.
1. Disconnect stator wires. The 2 pin connector disconnects from voltage regulator.
2. Remove stator mounting screws.
3. Reverse steps for installation (refer to wiring diagram in Section 8 for correct stator wire
connections).
NOTE: Apply Loctite 222 to threads of stator mounting screws.

b
b

51

51 Loctite “222” (92-809818)

a - Stator
b - Screw (3) M5 x 30
c - 2 Pin Connector

Stator Screw Torque

85 lb. in. (9.6 N·m)

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CHARGING & STARTING SYSTEM

Voltage Regulator/Rectifier Removal and Installation

1. Disconnect voltage regulator/rectifier wire connectors.
2. Remove mounting screws and remove voltage regulator/rectifier.
3. Reverse steps for installation (refer to wiring diagram section 8 for correct wire connec-
tions).
b

a - Voltage Regulator/Rectifier
b - Screw (2) M6 x 40
c - Connectors

Voltage Regulator/Rectifier Mounting Screw Torque

75 lb. in. (8.5 N·m)

Page 2B-22 90-883065 APRIL 2001

 CHARGING & STARTING SYSTEM

Starting System Components

Description
The function of the starting system is to crank the engine. 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 battery 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.
The starting system consists of the following components.
1. Battery
2. Starter Solenoid
3. Neutral Safety Switch
4. Starter Motor
5. Ignition Switch

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

Troubleshooting the Starting Circuit

Before beginning the starting circuit troubleshooting flow chart, following, check first for the
following conditions:
1. Make sure that battery is fully charged.
2. Check that control lever is in “NEUTRAL” position.
3. Check battery terminals for corrosion and loose connections.
4. Check start solenoid and starter for corrosion and loose connections.
5. Check cables and wiring for frayed and worn insulation.
6. Check 20 Amp fuse.

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CHARGING & STARTING SYSTEM

Starter Solenoid Test

1. Inspect starter solenoid for cracks, loose terminals or loose terminal lead connections.
2. Connect ohm meter between terminals of starter solenoid.
3. Connect the BLACK lead from solenoid to battery negative (–) terminal and momentarily
connect the BROWN lead to the positive (+) terminal of battery.
4. Verify continuity between the starter solenoid terminals when 12 volts are applied.

b
a - BROWN Lead
b - Starter Solenoid
c - BLACK Lead
d - Battery

The following “STARTING CIRCUIT TROUBLESHOOTING FLOW CHART” is designed as

an aid to troubleshooting the starting circuit. This flow chart will accurately locate any exist-
ing malfunction. Location of “TEST POINTS” (called out in the chart) are numbered in dia-
gram below.

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 CHARGING & STARTING SYSTEM

FUSE HOLDER ASSEMBLY BRN YEL/RED

15 RED/PUR

YEL/RED
BRN
6

RED

BLK
BLK
STARTER
3

YEL/RED
RED/PUR
BLK
(with
RED SLEEVES) DIODE
BLK STARTER
(with SOLENOID
NEUTRAL

BLK
YEL SLEEVES)
1 START
SWITCH
7
4
5
2
BLK = Black
BLU = Blue
BRN = Brown
GRY = Gray
GRN = Green + – BLK
ORN = Orange IGNITION SWITCH
PNK = Pink
PUR = Purple BATTERY
RED = Red
TAN = Tan
WHT = White
YEL = Yellow

Starting Circuit Troubleshooting Flow Chart

Starter Motor Does Not Turn

SAFETY WARNING: Disconnect BLACK (with Yellow

Sleeve) (starter motor) cable from starter solenoid test
point 1 BEFORE making tests 1-thru-7 to prevent unex-
pected 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, on next page.
post and the powerhead.
• Check cable for loose or corroded connections.
• Check cable for open.

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CHARGING & STARTING SYSTEM

* 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 start-
c. Turn ignition key to “Start” position. er solenoid; proceed to TEST 7.

Electric Start Tiller Handle Model

No voltage reading; 12 Volt Reading
proceed to TEST 4. Neutral start switch is open or BLACK leads are
Defective starter solenoid. disconnected or damaged.

TEST 4
a. Connect voltmeter between common 12 Volt Reading*
engine ground and Test Point 4. Neutral start switch is open, or BROWN, or
No voltage reading; b. Turn ignition key to “Start” position. YEL/RED, or BLACK wire is open between
proceed to TEST 5. Test Points 4 and 3. Check diode adaptor if
equipped.

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 BLACK (with RED

12 Volt Reading*
sleeve) wire between battery (+) positive termi- Check fuse in RED wire between test points 5 and 6.
nal and Test Point 6. Check for open RED or RED/PUR wire between test
points 5 and 6.

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 (with YELLOW sleeve) (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 (with

12 Volt Reading*
Check BLACK (with YELLOW sleeve) cable
YELLOW sleeve) cable for poor connec-
at starter for loose or corroded connection, or
tion or open circuit.
open circuit. If cable is O.K., check starter mo-
tor.

Page 2B-26 90-883065 APRIL 2001

 CHARGING & STARTING SYSTEM

Starter Motor Servicing

Removal
WARNING
Always disconnect the battery and remove spark plug leads from spark plugs be-
fore working on motor.
1. Disconnect battery leads from battery and black starter motor lead from starter solenoid.
2. Remove upper mounting screws. Loosen bottom screw, lift up and remove starter.
a

a 58813

a - Starter Mounting Screw (3) M8 x 45

b - Starter Motor Lead

Disassembly
1. Remove 2 thru bolts and commutator end cap, taking care not to lose brush springs.
a c

a c
b
a - Thru Bolts
b - Commutator End Cap
c - Brush Springs

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CHARGING & STARTING SYSTEM

2. Remove the nut, washer, spring, pinion stopper and pinion drive assembly. You may
need to lightly clamp the armature in a vise while removing the nut.
NOTE: DISPOSE OF NUT AFTER REMOVING IT AND USE A NEW ONE FOR REAS-
SEMBLY.

e
c
b

c d

58223
a - Nut d - Spring
b - Washer e - Pinion
c - Pinion Stopper

3. Pull armature from starter frame.

f g h

d c d

a b e
a - Nut e - Pinion
b - Washer f - Drive End Cap
c - Spring g - Armature Shaft
d - Pinion Stopper (2) h - Washer

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 CHARGING & STARTING SYSTEM

Cleaning and Inspection

1. Clean all 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 ex-
cessive.
4. Check that the brush holder is not damaged or is not holding the brushes against the
commutator.
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. (0.8mm) to the full width of the insulation, make sure that the undercut
is flat.
b. Clean the commutator slots after undercutting.
c. De-burr the commutator lightly with No. 00 sandpaper, then clean the commutator.
d. Check the armature on a growler for shorts. See “TESTING”, following.
9. Open-circuited armatures often can be saved where an open circuit is obvious and re-
pairable. The most likely place for an open circuit is at the commutator bars. Long crank-
ing periods overheat the starter motor so that solder in the connections melts. The poor
connections cause arcing and burning of the commutator bars.
10. Repair bars, that are not too badly burned, by re-soldering the leads in bars (using rosin
flux solder) and turning down the commutator in a lathe to remove burned material, then
undercut the mica.
11. Clean out the copper or brush dust from slots between the commutator bars.
12. Check the armature for shorts and ground. See “TESTING”.

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CHARGING & STARTING SYSTEM

Testing
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. Re-
check after cleaning between commutator bars. If saw blade still vibrates, replace armature.

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, as shown.
2. If meter indicates continuity, armature is grounded and must be replaced.

Page 2B-30 90-883065 APRIL 2001

 CHARGING & STARTING SYSTEM

CHECKING POSITIVE BRUSHES AND TERMINALS

1. Connect ohmmeter (R x 1 scale) leads between positive brushes.
2. Ohmmeter must indicate full continuity (zero resistance). 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

TESTING NEGATIVE BRUSHES FOR GROUND

Set ohmmeter to (R x 1 scale). Place one lead of ohmmeter on the negative brush and the
other lead on the end cap (bare metal). If the meter indicates NO continuity, replace the neg-
ative brush. Repeat this procedure on the other negative brush.

b
a

a - Negative (–) Brushes

b - End Cap

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CHARGING & STARTING SYSTEM

Brush Replacement
IMPORTANT: Replace brushes that are pitted or worn to less than 1/4 in. (6.4mm) in
length.

e
c
f
g

b
a

a - Positive (+) Terminal

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

a c b

b a

a - Positive (+) Brushes

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

Page 2B-32 90-883065 APRIL 2001

 CHARGING & STARTING SYSTEM

Reassembly
1. Lubricate helix threads and drive end cap bushing with SAE 10W oil.
2. Install the pinion, pinion stopper, spring, second pinion stopper, washer, and NEW nut
onto armature shaft.
3. Lightly clamp the armature in a vise and torque nut to specified torque.

f g h

d c d

a e
b
a - Nut
b - Washer
c - Spring
d - Pinion Stopper (2)
e - Pinion
f - Drive End Cap
g - Armature Shaft
h - Washer
Starter Shaft Nut Torque
22.5 lb.-ft. (30.5 N·m)

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CHARGING & STARTING SYSTEM

4. Construct a brush retainer tool as shown.

Brush Retainer Tool Layout (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
1/2” = 12.7mm

Brush Retainer Tool Side View (Full Size)

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 CHARGING & STARTING SYSTEM

5. Place springs and brushes into brush holder and hold in place with brush retainer tool.
6. Lubricate bushing with one drop of SAE 10W oil. DO NOT over-lubricate.

a - Brush Retainer Tool

b - Bushing

7. Position armature into starter frame so that commutator end of armature is at end of
starter frame where permanent magnets are recessed 1 in. (25.4mm). Align marks (a)
as shown.
8. Install commutator end cap onto starter frame; align marks (b) as shown, and remove
brush retainer tool.
9. Install thru bolts (c) and torque to 70 lbs. in. (7.9 N·m).

c
c

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CHARGING & STARTING SYSTEM

Installation
1. Secure starter to block with (3) mounting screws. Tighten screws to specified torque.
Secure starter motor lead as shown.
a

a 58813

a - Starter Mounting Screw (3) M8 x 45

b - Starter Motor Lead

Starter Motor Mounting Screw Torque

22 lb. ft. (29 N·m)

Page 2B-36 90-883065 APRIL 2001