FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.

Repair Procedures





Removal

1. Disconnect the battery ground cable.
2. Remove the speedometer cable and the shift cable.
3. Disconnect the starter motor connector and terminal.
4. Remove the starter motor assembly.
5. Installation is the reverse order of removal.

Inspection

Brush
A brush worn down to the wear limit line should be replaced.





Brush Holder
Make sure there is no continuity between the (+) brush holder (A) and (-) plate (B). If there is continuity, replace the brush holder assembly.





Overrunning Clutch
Inspect the pinion and spline teeth for wear or damage. Replace if damaged. Also inspect the flywheel ring gear for damage.
Rotate the pinion. It should turn freely in a clockwise direction, and lock when turned counterclockwise.






Pinion Gap Adjustment

1. Disconnect the wire from the M-terminal.
2. Connect a 12V battery between the S-terminal and the M-terminal.
3. Set the switch to "ON", and the pinion will move out.

CAUTION:
This test must be performed quickly (in less than 5 seconds) to prevent damage to the coil.




4. Check the pinion to stopper clearance (pinion gap)with a feeler gauge. If the pinion gap is out of specification,adjust by adding or removing washers between the solenoid and the front bracket.

Solenoid Pull-in Test
1. Disconnect the connector from the M-terminal.
2. Connect a 12V battery between the S-terminal and M-terminal.

CAUTION:
This test must be performed quickly (in less than 5 seconds) to prevent damage to the coil.

3. If the pinion moves out, the pull-in coil is good. If it doesn't, replace the solenoid.





Solenoid Hold-in Test
1. Disconnect the connector from the M-terminal.
2. Connect a 12V battery between the S-terminal and the body.

CAUTION:
This test must be performed quickly (in less than 5 seconds) to prevent damage to the coil.

3. If the pinion remains out, everything is in order. If the pinion moves in, the hold-in circuit is open. Replace the magnetic switch.





Solenoid Return Test
1. Disconnect the connector from the M-terminal.
2. Connect a 12V battery between the M-terminal and the body.

CAUTION:
This test must be performed quickly (in less than 5 seconds) to prevent damage to the coil.

3. Pull out the pinion and then release it. If the pinion returns quickly to its original position, everything is in order. If it doesn't, replace the solenoid.





Performance Test (NO-LOAD)
1. Make the no-load circuit test as shown.
2. After adjusting the rheostat until the battery voltage shown on the voltmeter reads 11.5 volts, confirm that the maximum amperage draw is within the specifications and that the starter motor turns smoothly and freely.