BATTERY CHARGING SYSTEM AND STARTING SYSTEM

ELECTRICAL
Section 2B - Battery Charging System and Starting System
Table of Contents
2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 System Wired for Split Output . . . . . . . . . . 2B-9
B
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 System Wired for 40 Ampere
Battery Charging System Description . . . . . . 2B-3 Output to Isolator . . . . . . . . . . . . . . . . . . . . 2B-10
Battery Charging System Troubleshooting . . 2B-3 Flywheel/Starter Assembly . . . . . . . . . . . . . . . 2B-11
General Troubleshooting . . . . . . . . . . . . . . 2B-3 Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . . 2B-12
Alternator System . . . . . . . . . . . . . . . . . . . . 2B-4 Starter Circuit Troubleshooting Flow Chart 2B-13
Troubleshooting Alternator System . . . . . 2B-4 Starter Removal and Installation . . . . . . . . 2B-14
Starter System . . . . . . . . . . . . . . . . . . . . . . . 2B-7 Starter Cleaning, Inspection and Testing . 2B-17
Incorporating a Battery Isolator With V-6 40 Amp
Charging System . . . . . . . . . . . . . . . . . . . . . 2B-8

Specifications
Starter Draw (No Load) 40 Amperes
Starter Draw (Under Load) 175 Amperes
Battery Rating 670 Marine Cranking Amps (MCA)
or 520 Cold Cranking Amps (CCA)
Alternator Output 12 Amperes @ 3000 RPM

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BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Special Tools
Multi Meter DVA Tester 91-99750A1

DMT 2000 Digital Tachometer/Multi-meter (91-854009A1)

Description Part Number

Hydrometer Obtain Locally
Ammeter Obtain Locally

Page 2B-2 90-877837 NOVEMBER 1999

 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Battery Charging System Description

The battery charging system components are the flywheel permanent magnets, stator, volt-
age regulator/rectifier and battery. The rotating permanent magnets induce an alternating
current (AC) in the stator coils. The AC current is rectified to direct current (DC) by the volt-
age regulator/rectifier. The DC output from the voltage regulator/rectifier is used to charge
the battery. The voltage regulator/rectifier also senses the battery voltage as a measure of
the battery’s state of charge and thereby regulates the DC current flow to the battery. In this
manner, the battery charge is maintained and the battery is protected from an overcharge
condition.

b
a

e 51806
a - Stator
b - Starter Solenoid
c - To Tachometer
d - Voltage Regulator/Rectifier
e - 12 Volt Battery

Battery Charging System Troubleshooting

General Troubleshooting
A fault in the battery charging system will usually cause the battery to become UNDER-
CHARGED. A defective VOLTAGE REGULATOR may also allow the system to OVER-
CHARGE the battery.
If a problem exists in the charging system, visually check the following:
1. Check for correct battery polarity [RED cable to (+) POSITIVE battery terminal].
2. Check for loose or corroded battery terminals.
3. Check condition of the battery.
4. Visually inspect all wiring between stator and battery for cuts, chafing and disconnected,
loose or corroded connections.
5. Excessive electrical load (from too many accessories) will cause battery to run down,
even if the system is operating correctly.
If the system is still OVERCHARGING the battery, the VOLTAGE REGULATOR is most like-
ly defective and should be replaced.
If the battery is UNDERCHARGED, proceed with REGULATOR, STATOR, and RECTIFIER
tests, following.

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BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Alternator System
STATOR TEST (ALTERNATOR COILS ONLY)
NOTE: Stator can be tested without removing from engine.
1. Disconnect 2 YELLOW stator leads from bullet connectors to voltage regulator/rectifier.
2. Use an ohmmeter and perform the following test:

15 AMP SYSTEM
Test Leads To- Resistance (Ohms) Scale Reading
Connect test leads between 2
.25-.45* Rx1
YELLOW stator leads
RED test lead to 1 YELLOW stator
lead, and BLACK test lead to en-
No
gine ground if stator is mounted or R x 1000
Continuity
to steel frame of stator (if off en-
gine)

40 AMP SYSTEM
Test Leads To- Resistance (Ohms) Scale Reading
Connect test leads between 2
short YELLOW and 2 long YEL- .25-.45* Rx1
LOW stator leads
RED test lead to 1 short YELLOW
(or long YELLOW) stator lead, and
No
BLACK test lead to engine ground R x 1000
Continuity
if stator is mounted or to steel
frame of stator (if off engine)

* Resistance of these windings generally is less than one ohm. A reading, that resembles
a short, is acceptable. Copper wire is an excellent conductor but will have noticeable differ-
ences from cold to hot. Reasonable variation from specified reading is acceptable.
3. If meter readings are other than specified, replace stator assembly Refer to stator as-
sembly replacement in Section 2A.
Troubleshooting Alternator System
WARNING
Before connecting or disconnecting any electrical connection, battery cables
MUST BE REMOVED from battery to prevent possible personal injury or damage to
equipment.
IMPORTANT: The charging system may be connected to one or more batteries during
these tests. However, these batteries MUST BE fully charged. These batteries MUST
NOT BE connected to any other charging source.
IMPORTANT: Check that all connections are tight prior to starting tests. Ensure that
the battery posts and terminals are clean and making good contact. Verify with test
equipment that wiring harnesses are not at fault.

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 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

DETERMINING CAUSE OF PROBLEM

1. Connect outboard battery leads to battery(s) that are known to be in good condition and
are fully charged.
2. Check voltage at battery(s) with an analog volt meter. Digital voltmeters are not recom-
mended as they may be inaccurate due to interference from ignition system.
3. Start engine and run at 1000 RPM. Voltage at battery should rise to and stabilize at ap-
proximately 14.5 volts if system is operating properly. If voltage does not increase from
previously checked battery voltage values, refer to “NO OUTPUT,” following, for trou-
bleshooting procedures. If voltage exceeds 16 volts and DOES NOT return down to and
stabilize at 14.5 volts, refer to “CONSTANT HIGH OUTPUT,” following for troubleshoot-
ing procedures.
PROBLEM: CONSTANT HIGH OUTPUT
1. Remove flywheel and visually inspect stator. Discoloration of one or more poles, or
burned windings will require replacement of stator.
2. If no visual defects of stator are found, reinstall flywheel. Temporarily install ammeter
(of sufficient size to carry 50 amperes) in series with the RED output lead (MALE bullet
lead) of the regulator and the starter solenoid.
15 AMP SYSTEM
3. Remove 1 YELLOW stator lead from bullet connector. Run engine at 1000-2000 RPM.
Any output current indicates stator is shorted to ground. Replace stator.
4. If there is no output with YELLOW lead disconnected, the regulator is defective.
40 AMP SYSTEM
5. Remove 1 short and 2 long YELLOW stator leads from their bullet connectors. Run en-
gine at 1000-2000 RPM. If no output current is observed, disconnect 2 short YELLOW
leads and 1 long YELLOW lead. Repeat the test with the second long YELLOW lead
connected. Any output indicates stator is shorted to ground. Replace stator.
6. If there is no output with either short or long YELLOW leads disconnected, the regulators
are defective.
PROBLEM: NO OUTPUT
IMPORTANT: Regulator(s) MUST have a good ground. Verify a clean contact surface
exists between regulator case, powerhead and attaching hardware.
1. Check voltage on either RED wire to regulator (bullet connectors). These leads must
indicate battery voltage when the key is in the RUN position. If battery voltage is NOT
present, the key switch or wiring between the key switch and the test point is defective.
Refer to Wiring Diagram, Section 2A.
2. Connect an AC voltmeter to YELLOW lead bullet connector on the regulator. If the AC
voltage at idle or above is greater than 16 VAC, the regulator is defective.
NOTE: The tachometer signal is provided by the regulator. It is possible to still have an accu-
rate tachometer signal with a defective regulator.
REGULATION VOLTAGE CHECK
NOTE: Battery must be fully charged before testing regulation voltage. A low battery will not
allow an accurate reading of regulation voltage.
1. Turn on all electrical accessories and crank engine for 20 seconds with the ignition lan-
yard switch turned off. This will discharge battery slightly.

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BATTERY CHARGING SYSTEM AND STARTING SYSTEM

2. Start engine and observe battery voltage. Voltage should slowly rise to approximately
14 to 15 volts. If voltage does not rise, repeat previous tests for stator and regulator.
NOTE: If a digital voltmeter is used for this reading, measure voltage at the battery and keep
meter as far away from engine as possible. This will reduce the possibility of erroneous read-
ings from ignition noise.
VOLTAGE REGULATOR TEST (USING OHM METER)
IMPORTANT: Make sure meter is “zeroed” by shorting meter leads together after
changing selector knob to appropriate setting. The meter reading must read “0”
Ohms.
IMPORTANT: The following regulator tests should be performed as soon as possible
after suspected regulator failure. A “cold” regulator may test “GOOD” when in fact
it is defective when “warm”.
Disconnect all voltage regulator wires.
Using Ohm meter, perform each Ohms test listed below:

Test Leads To- Resistance (Ohms) Scale

Diode Check: Connect NEGATIVE
(–) ohm lead to either YELLOW
100-400 R x 10
lead. Connect POSITIVE (+) test
lead to thick RED lead.
Diode Check: Connect NEGATIVE
(–) ohm lead to thick RED lead.
40K to ∞ R x 1K
Connect POSITIVE (+) ohm lead
to either YELLOW lead.
SCR Checks: Connect NEGATIVE
(–) ohm lead to either YELLOW
10K to ∞ R x 1K
lead. Connect POSITIVE (+) ohm
lead to case ground.
Tachometer Circuit Check: Con-
nect NEGATIVE (–) ohm lead to
10K to 30K R x 1K
case ground. Connect POSITIVE
(+) ohm lead to GRAY lead.

REMOVAL OF VOLTAGE REGULATOR

1. Disconnect all voltage regulator wires. Remove two screws securing voltage regulator
to ignition plate.

a - Voltage Regulator/Rectifier
2. Remove voltage regulator/rectifier from powerhead.

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 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

INSTALLATION OF VOLTAGE REGULATOR/RECTIFIER

1. Position regulator over ignition plate. Secure with two screws.
2. Connect YELLOW, RED and GRAY (as required) leads to their respective bullet connec-
tors.
Starter System
STARTER SYSTEM COMPONENTS
1. Battery
2. Starter Solenoid
3. Neutral Start Switch
4. Starter Motor
5. Ignition Switch
DESCRIPTION
The function of the starting system is to crank the engine. The battery supplies electricity
to activate the starter motor. When the ignition switch is turned to the “START” position, the
starter solenoid is energized and completes the starter circuit between the battery and start-
er.
The neutral start switch opens the starter circuit when the shift control lever is not in neutral
thus preventing accidental starting when the engine is in gear.

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.

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BATTERY CHARGING SYSTEM AND STARTING SYSTEM

TROUBLESHOOTING THE 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.

g 2
6 1 a

b
7
f

3
e
2
6 1
5 4 c

a - Starter Solenoid
b - Starter
c - Neutral Start Switch
d - Ignition Switch
e - 20 Ampere Fuse
f - Starter Solenoid
g - Battery
Incorporating a Battery Isolator With V-6 40 Amp Charging System
A battery isolator will allow the charging system to charge both the starting battery and an
auxiliary battery at the same time while preventing accessories, connected to the auxiliary
battery, from drawing power from the cranking battery.
1. Install the isolator as prescribed by the manufacturer.
IMPORTANT: After electrical connections are made, coat all terminal connections us-
ing Quicksilver Liquid Neoprene (92-25711) to avoid corrosion.

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 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

2. Using BATTERY ISOLATOR HARNESS KIT 84-815366A3, charging system can be

wired to provide either 20 amps to auxiliary battery and 20 amps to cranking battery or
40 amps to isolator.
System Wired for Split Output
20 AMPERES TO AUXILIARY BATTERY; 20 AMPERES TO CRANKING BATTERY

c
d

f
g

a - Starter Solenoid
b - RED Leads – Engine Harness from Upper Regulator to
Start Solenoid
c - Disconnect (and discard) Engine Harness RED Leads to
Lower Regulator
d - Upper Regulator
e - Lower Regulator
f - Jumper Wire (from kit)
g - RED Pigtail Cable (from kit) to Auxiliary Battery “+”
Terminal
h - BLACK Cable (from kit) Route from Auxiliary Battery “–”
Terminal to suitable Engine Ground

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BATTERY CHARGING SYSTEM AND STARTING SYSTEM

System Wired for 40 Ampere Output to Isolator

IMPORTANT: After electrical connections are made, coat all terminal connections us-
ing Quicksilver Liquid Neoprene (92-25711) to avoid corrosion.

b
h
j
c

h
i
e

a - Starter Solenoid
b - RED Lead to Starter Solenoid
c - Battery Isolator
d - Start Battery
e - Auxiliary Battery
f - RED pigtail Cable (from kit) to Battery Isolator
g - BLACK Cable (from kit) route from Auxiliary Battery “–”
Terminal to Engine Ground
h - Plug (from kit)
i - Lower Regulator
j - Upper Regulator
k - RED Leads – Engine Harness from Regulators to Starter
Solenoid

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 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Flywheel/Starter Assembly

2
25 3
15 4 5 1
11
24 6 12
13

23 7
16 8
22
9
21 17 10
14

19 20
18
15

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 DECAL-Sport Jet 175XR2
2 1 PLUG
3 1 COVER KIT-Flywheel
4 2 WASHER
5 2 SCREW (.190-32 x .380)
6 1 MARKER-Timing
7 1 PLUG
8 1 NUT (.625-18) 120 163
9 1 WASHER
10 1 FLYWHEEL ASSEMBLY
11 4 SCREW (#10-32 x 1.00)
12 4 LOCKWASHER (#10)
13 1 STATOR ASSEMBLY
14 1 TRIGGER PLATE ASSEMBLY
15 2 COLLAR-Starter Cap
16 1 DECAL-Start In Gear
17 1 DECAL-High Voltage
18 1 WIRE ASSEMBLY (12.500 in.) (BLACK)
19 1 NUT (.250-20)
20 1 LOCKWASHER (.250)
21 1 STARTER ASSEMBLY
22 1 BOOT (Red)-Starter Lead
23 1 SCREW W/ LOCKWASHER (.250-20 x .625)
24 1 WIRE ASSEMBLY (6.00 in.) (BLACK)
25 2 STOP (Rubber)

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BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Starter Assembly

2
8

3 5

4
1
6

8
9
7 11 10
9
9
13
14
12

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 STARTER ASSEMBLY
2 1 DRIVE KIT-Pinion
3 1 PINION ASSEMBLY-Drive
4 1 CAP ASSEMBLY-Drive End
5 2 THRU BOLT
6 2 O RING-Thru Bolt
7 1 ARMATURE
8 2 O RING-Starter Frame
9 1 BRUSH/SPRING KIT
10 2 SCREW-Brush Holder
11 1 HOLDER-Brush
12 1 CAP-Com End
13 1 WASHER-Insulator-Brush Post
14 1 NUT-Brush Post

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 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Starter Circuit Troubleshooting Flow Chart

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 pow-
erhead 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 TEST 4 Defective starter solenoid

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

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

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 Points
POSITIVE terminal and Test Point 6.
5 and 6.
Check for open RED wire between Test Points
5 and 6.

*Battery Voltage

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BATTERY CHARGING SYSTEM AND STARTING SYSTEM

TEST 7
a. Connect voltmeter between common engine and Test Point 1.
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

Starter Removal and Installation

REMOVAL

CAUTION
Disconnect battery leads from battery before removing starter.
1. Disconnect BLACK ground cable from starter.
2. Disconnect BLACK (with YELLOW sleeve) cable from starter.
3. Remove 4 bolts and upper and lower starter clamps. Lift starter from engine.

a - BLACK (with YELLOW sleeve) POSITIVE (+) 12-

b - BLACK Ground Cable

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 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

INSTALLATION
1. Slide rubber collars on starter.
2. If the removed starter was equipped with a spacer replace spacer on upper collar.
a
a

b 11645
a - Rubber Collar
b - Spacer (If Equipped)
3. Install starter to engine with starter clamps. Make sure that black ground cable is fas-
tened, along with lower mounting bolts. Torque bolts to 210 lb. in. (23.5 N·m).
4. Reconnect yellow cable to positive (+) terminal on starter.
5. Reconnect black ground cable to terminal on starter.
DISASSEMBLY
1. Remove starter as outlined in “Starter Removal and Installation”.
2. Remove 2 through bolts from starter.
a

b
11646
a - Through Bolts
b - Commutator End Cap
3. Tap commutator end cap to loosen and remove from frame. Do not lose brush springs.
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.

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BATTERY CHARGING SYSTEM AND STARTING SYSTEM

b. Remove 2 bolts securing NEGATIVE (-) brushes and brush holder to end cap.

c
b a

e
e

c
d b
11656
a - Brush Holder
b - POSITIVE Brushes
c - NEGATIVE Brushes
d - POSITIVE Terminal
e - Bolts (Fasten NEGATIVE Brushes and Holder)
5. Remove armature (with drive end cap) from starter frame.
6. Remove locknut and remove drive assembly from armature shaft.

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

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 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Then remove parts from shaft.

e f g
a b c d

11658
a - Locknut
b - Spacer
c - Spring
d - Drive Assembly
e - Drive End Cap
f - Armature Shaft
g - 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 exces-
sive.
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. (6.4mm) 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.
d. Recheck the armature on a growler for shorts as specified in the following procedure
(“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 commutator bars.
9. Repair bars, that are not excessively burned, by resoldering the leads in bars (using ros-
in flux solder) and turning down the commutator in a lathe to remove burned material,
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”).

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BATTERY CHARGING SYSTEM AND 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. 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.

11675
Checking Positive Brushes and Terminal

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 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

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.

11673
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, replace the
NEGATIVE brush. Repeat this procedure on the other NEGATIVE brush.

a b

11674
a - NEGATIVE (-) Brushes
b - End Cap

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BATTERY CHARGING SYSTEM AND STARTING SYSTEM

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

b
i

d h
d

e
c
f
g

11660
a - End Cap
b - POSITIVE Brushes
c - POSITIVE Terminal
d - Insulating Bushing
e - Washer
f - Split Washer
g - Hex Nut
h - Long Brush Lead
i - Push Lead into Slot

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 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

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

b
a c

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.
e f g
a b c d

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.

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BATTERY CHARGING SYSTEM AND STARTING SYSTEM

6. To prevent damage to brushes and springs when installing commutator end cap, it is
recommended that a brush retaining tool be made as shown:

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

7. Lubricate bushing (located in commutator end cap) with one drop of SAE 10W oil. DO
NOT over lubricate.

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 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

8. Place springs and brushes into brush holder and hold in place with brush retainer tool

11661
a - Brush Retainer Tool
b - Bushing (DO NOT over lubricate)
9. Install armature into starter frame and align match marks (a). Install commutator end cap
onto starter frame and align match marks (b). Remove brush retainer tool. Install
through bolts (c) and torque to 70 lb. in. (8.0 N·m)

c c

11648
a - Alignment Marks
b - Alignment Marks
c - Bolts [Torque to 70 lb. in. (8.0 N·m)]

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BATTERY CHARGING SYSTEM AND STARTING SYSTEM

STARTER SOLENOID TEST

1. Disconnect all wires from solenoid.
2. Use an ohmmeter (R x1 scale) and connect meter leads between solenoid terminals 1
and 2.
3. Connect a 12-volt power supply between solenoid 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.

b a
1 3

4
a
2 b

51809
a - 12-VOLT Supply
b - VOA Leads

Page 2B-24 90-877837 NOVEMBER 1999