CHARGING & STARTING SYSTEM

ELECTRICAL
Section 2B - Charging & Starting System
Table of Contents
2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Digital Meter . . . . . . . . . . . . . . . . . . . . . . . . . 2B-14
B
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Starting System Components . . . . . . . . . . . . . 2B-18
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4 Description . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-18
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6 Starting System Schematic . . . . . . . . . . . . 2B-18
Recommended Battery . . . . . . . . . . . . . . . . 2B-6 Troubleshooting the Starting Circuit . . . . . . . . 2B-19
Operating Engine Without Battery . . . . . . 2B-6 Starter Solenoid Test . . . . . . . . . . . . . . . . . . 2B-19
Battery Charging System Troubleshooting 2B-6 Starter Relay . . . . . . . . . . . . . . . . . . . . . . . . 2B-20
Battery Charging System . . . . . . . . . . . . . . . . . 2B-7 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-21
Description (25 Ampere) . . . . . . . . . . . . . . 2B-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-21
Wiring Diagram (25 Ampere) . . . . . . . . . . . 2B-7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-22
Alternator System Test . . . . . . . . . . . . . . . . . . . 2B-8 Cleaning and Inspection . . . . . . . . . . . . . . . 2B-24
25 Ampere Stator . . . . . . . . . . . . . . . . . . . . 2B-8 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-26
Stator Coil Resistance Test . . . . . . . . . . . . . . . 2B-9 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-27
Rectifier/Regulator Diode Test . . . . . . . . . . . . 2B-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-31
Analog Meter . . . . . . . . . . . . . . . . . . . . . . . . 2B-10

90-881980R1 NOVEMBER 2001 Page 2B-1

CHARGING & STARTING SYSTEM

Specifications
Alternator Type: Three Phase Stator Coil (12 Pole)
Alternator Output 12.0 V; 25 Amps. (300 Watts)
(Rectified/Regulated)
Stator Coil - Peak Voltage:
@ 400 rpm (Cranking) 10 - 18 V
CHARGING @ 750 rpm (Idle) 16 - 24 V
SYSTEM @ 1500 rpm 16 - 24 V
Readings taken @ @ 3500 rpm 16 - 24 V
68°F (20°C). Stator Coil Resistance 0.2 - 0.8 Ω
Rectifier/Regulator Output - Peak
Voltage:
@ 750 rpm (Idle) 12.5 - 15.5 V
@ 1500 rpm 13.0 - 16.0 V
@ 3500 rpm 13.0 - 16.0 V
Quicksilver Tachometer Setting “6P” or “4”
Electric Start:
Starter Type Sliding Gear
Model/Manufacturer S114-838A/Hitachi
Output 1.4 kW - 12 V
Rating 30 Seconds
Reduction Gear Ratio 7.85 (102:13)
Brush:
Length 0.610 in. (15.5 mm)
STARTING
Minimum Length 0.374 in. (9.5 mm)
SYSTEM
Commutator:
Diameter 1.113 in. (29.0 mm)
Minimum Diameter 1.100 in. (28.0 mm)
Undercut 0.020 in. (0.5 mm)
Undercut Limit 0.008 in. (0.2 mm)
Ampere Draw Under:
(Load) 165 Amps
(No Load) 80 Amps
Battery Rating
Minimum Requirement 465 Marine Cranking Amps (MCA)
or 350 Cold Cranking Amps (CCA)
BATTERY
For operation below 32° F (0° C) 1000 Marine Cranking Amps (MCA) or
775 Cold Cranking Amps (CCA)
Ampere-Hours (Ah) 70 - 100

Page 2B-2 90-881980R1 NOVEMBER 2001

 CHARGING & STARTING SYSTEM

Special Tools
1. Brush Holder P/N91-875216

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

3. Stator Coil Test Harness 91-881824

58676

90-881980R1 NOVEMBER 2001 Page 2B-3

CHARGING & STARTING SYSTEM

STARTER MOTOR

110
22
21

20 22

26

19
1

2
10

23 11
4 5
12
5
25
24
14 5
9 3
95
11
13
26 11
15
6
16

7
95
17
29
28 18 8
27
30
31

95 2-4-C with Teflon

110 4-Stroke Outboard Oil

Page 2B-4 90-881980R1 NOVEMBER 2001

 CHARGING & STARTING SYSTEM

STARTER MOTOR
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb.ft. Nm
– 1 STARTER MOTOR
1 1 STATOR
2 1 ARMATURE
3 1 BRUSH HOLDER ASSEMBLY
4 1 BRUSH SET
5 4 BRUSH SPRING
6 1 BRACKET
7 2 SCREW (M4 X 16 MM) 18 2
8 2 SCREW (M6 X 120 MM) 70 8
9 1 GEAR ASSEMBLY
10 1 CLUTCH
11 1 WASHER KIT
12 1 BRACKET
13 1 RING GEAR
14 1 GASKET
15 1 BEARING
16 1 PINION SHAFT
17 3 IDLER GEAR
18 1 BRACKET
19 1 COVER
20 2 SCREW (M6 X 52 MM) 70 8
21 1 PINION
22 1 STOP SET
23 1 LEVER
24 1 COVER
25 1 STARTER RELAY
26 3 SCREW (M8 X 45 MM) 156 13 17.5
27 1 TERMINAL
28 1 LOCKWASHER
29 1 NUT
30 1 NUT
31 1 COVER

90-881980R1 NOVEMBER 2001 Page 2B-5

CHARGING & STARTING SYSTEM

Battery
Recommended 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.
Operating Engine Without Battery
If desired (or in an emergency), engines equipped with an electric start and alternator can
be started and operated without a battery (either disconnected or removed) if “WARNING”,
below, is followed.

WARNING
Before operating engine with battery leads disconnected from battery, disconnect
the three wire (stator harness plug) from rectifier.

Battery Charging System Troubleshooting

CAUTION
The charging system may be damaged by: 1) reversed battery cables, 2) running the
engine with battery cables disconnected and stator leads connected to rectifier, 3)
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 rectifier. See “RECTIFIER TEST”.
2. Check for loose or corroded battery connections.
3. Visually inspect wiring between stator and battery for cuts, chafing; and 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 rectifier tests.

Page 2B-6 90-881980R1 NOVEMBER 2001

 CHARGING & STARTING SYSTEM

Battery Charging System

Description (25 Ampere)
The battery charging system components are the stator coils, rectifier/regulator and battery.
Alternating current (generated in the stator coils) flows to the rectifier/regulator, which
changes the alternating current to a regulated direct current for charging the battery.
Wiring Diagram (25 Ampere)
BLK WHT BLK WHT

a 2 WHT 1

WHT
RED RED WHT d
BLK

RED

e
RED

c 30 (A) 3
BLK = Black
BLU = Blue
BRN = Brown
GRY = Gray
GRN = Green
ORG = Orange
PNK = Pink
BLK BLK PUR = Purple
RED = Red
TAN = Tan
BLK (with RED Sleeve) WHT = White
YEL = Yellow
4 b
a - Rectifier/Regulator
b - 12V Battery
c - Fuse-30A
d - Stator Coil
e - Connector

90-881980R1 NOVEMBER 2001 Page 2B-7

CHARGING & STARTING SYSTEM

Alternator System Test

25 Ampere Stator
1. Check battery voltage at battery with engine running.
2. If battery voltage is above 14.5-15.0 volts, replace voltage regulator/rectifier. Check con-
dition of battery as overcharging may have damaged battery.
3. If battery voltage is below 14.5 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 rectifier/regulator) wire
bullet connector from the RED engine wiring harness.
6. Connect RED (+) ammeter lead to RED voltage rectifier/regulator wire and the BLACK
(–) ammeter lead to the RED engine wiring harness.
7. Secure starter wires away from flywheel.
8. With engine running at the indicated rpm, the ammeter should indicate the following ap-
propriate amperes:

24
22
20
18
Alternator current (Amps)

16
14
12
10
8
6
4
2
0
0 1 2 3 4 5 6
RPM x 1000
9. A reading of 22 amperes at 6000 rpm indicates the charging system is functioning prop-
erly.
10. If ammeter reads less than required amperes @ 6000 rpm, test the stator (refer to “Sta-
tor Coil Resistance Test”). If stator tests OK, replace rectifier/regulator.

Page 2B-8 90-881980R1 NOVEMBER 2001

 CHARGING & STARTING SYSTEM

Stator Coil Resistance Test

1. Plug test harness (91-881824) into stator harness and perform test as specified in chart
below.
• Out of specification - replace.

91-881824

a
91-854009A1

GRN 1 GRN 2

BLACK
RED
58658

58676

a a

GRN 1 GRN 3 GRN 2 GRN 3

BLACK

BLACK
RED

RED

58676

a - To Stator Harness
NOTE: Use ohm meter and test harness 91-881824 while performing test.

METER TEST LEADS METER SCALE READING (
)

RED BLACK
TEST HARNESS LEADS
GREEN 1 GREEN 2 RX1 0.2 - 0.8
GREEN 1 GREEN 3
GREEN 2 GREEN 3

90-881980R1 NOVEMBER 2001 Page 2B-9

CHARGING & STARTING SYSTEM

Rectifier/Regulator 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.
Install Stator Coil Test Harness 91-881824 onto voltage regulator/rectifier.
POSITIVE SIDE OF BRIDGE DIODE TEST 1:
1. Set Ohm meter to R X 10 scale.
2. Connect RED (+) meter lead to RED regulator lead.
3. Connect BLACK (–) meter lead to each of GREEN regulator test harness leads.

91-881824

91-99750A1

BLACK

RED
58658

58676

a - To Voltage Regulator/Rectifier
TEST RESULTS:
100 - 300 OHMS

Page 2B-10 90-881980R1 NOVEMBER 2001

 CHARGING & STARTING SYSTEM

DIODE TEST 2:
1. Set Ohm meter to R X 1k scale.
2. Connect BLACK (–) meter lead to RED regulator lead.
3. Connect RED (+) meter lead to each of GREEN regulator test harness leads.

91-881824

91-99750A1

BLACK
RED
58658

58676

a - To Voltage Regulator/Rectifier
TEST RESULTS:
∞ OHMS (No needle movement)

90-881980R1 NOVEMBER 2001 Page 2B-11

CHARGING & STARTING SYSTEM

GROUND SIDE OF BRIDGE DIODE TEST 3:

1. Set Ohm meter to R X 1k scale.
2. Connect RED (+) meter lead to BLACK ground wire.
3. Connect BLACK (–) meter lead to each of GREEN regulator test harness leads.

91-881824

91-99750A1

BLACK

RED
58658

58676

a - To Voltage Regulator/Rectifier
TEST RESULTS:
∞ OHMS (No needle movement)

Page 2B-12 90-881980R1 NOVEMBER 2001

 CHARGING & STARTING SYSTEM

DIODE TEST 4:
1. Set Ohm meter to R X 10 scale.
2. Connect BLACK (–) meter lead to BLACK ground lead.
3. Connect RED (+) meter lead to each of GREEN regulator test harness leads.

91-881824

a
91-99750A1

BLACK
RED
58658

58676

a - To Voltage Regulator/Rectifier
TEST RESULTS:
100 - 300 OHMS

90-881980R1 NOVEMBER 2001 Page 2B-13

CHARGING & STARTING SYSTEM

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.
Install Stator Coil Test Harness 91-881824 onto voltage regulator/rectifier.
POSITIVE SIDE OF BRIDGE DIODE TEST 1:
1. Set meter to .
2. Connect RED (+) meter lead to RED regulator lead.
3. Connect BLACK (–) meter lead to each of GREEN regulator test harness leads.

91-881824

a
91-854009A1

BLACK

RED
58658

58676

a - To Voltage Regulator/Rectifier
TEST RESULTS:
No continuity - Ouch - OL

Page 2B-14 90-881980R1 NOVEMBER 2001

 CHARGING & STARTING SYSTEM

DIODE TEST 2:
1. Set meter to .
2. Connect BLACK (–) meter lead to RED regulator lead.
3. Connect RED (+) meter lead to each of GREEN regulator test harness leads.

91-881824

a
91-854009A1

BLACK
RED
58658

58676

a - To Voltage Regulator/Rectifier
TEST RESULTS:
0.4 - 0.85 OHMS

90-881980R1 NOVEMBER 2001 Page 2B-15

CHARGING & STARTING SYSTEM

GROUND SIDE OF BRIDGE DIODE TEST 3:

1. Set meter to .
2. Connect RED (+) meter lead to BLACK ground wire.
3. Connect BLACK (–) meter lead to one GREEN regulator test harness lead. Test. Con-
nect BLACK (–) meter lead to each of other GREEN leads.

91-881824

a
91-854009A1

BLACK

RED
58658

58676

a - To Voltage Regulator/Rectifier
TEST RESULTS:
0.4 - 0.85 OHMS

Page 2B-16 90-881980R1 NOVEMBER 2001

 CHARGING & STARTING SYSTEM

DIODE TEST 4:
1. Set meter to .
2. Connect BLACK (–) meter lead to BLACK ground lead.
3. Connect RED (+) meter lead to each of 3 GREEN regulator test harness leads.

91-881824

a
91-854009A1

BLACK
RED
58658

58676

a - To Voltage Regulator/Rectifier
TEST RESULTS:
No Continuity - Ouch - OL

90-881980R1 NOVEMBER 2001 Page 2B-17

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.
Starting System Schematic

a c
b
BRN

BRN
f

RED
BRN/WHT

BLK BLK (with RED Sleeve)

e
BLK

a - Starter Motor d - 12 Volt Battery

b - Starter Solenoid e - Starter Relay
c - Engine Wiring Harness f - 30 Ampere Fuse
Connector

Page 2B-18 90-881980R1 NOVEMBER 2001

 CHARGING & STARTING SYSTEM

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 terminals for corrosion and loose connections.
4. Check cables and wiring for frayed and worn insulation.
5. Check 30 Amp fuse.
6. Check starter relay.
7. Check shift position switch. Refer to Section 2A Ignition.
Starter Solenoid Test
1. Inspect starter solenoid for cracks, loose terminals or loose terminal lead connections.
2. Connect ohm meter between relay (magnetic switch) terminals as shown.
3. Connect the starter motor body to the negative (–) battery terminal.
4. Connect the BROWN/WHITE lead to the positive (+) battery terminal.
5. Check that there is continuity between the relay (magnetic switch) terminals.
6. Check that there is no continuity after the BROWN/ WHITE lead is removed.
NOTE: The pinion gear should be pushed out while the magnet switch is ON.

b
a

c
a - Relay Terminals
b - BROWN/WHITE Lead
c - Battery

90-881980R1 NOVEMBER 2001 Page 2B-19

CHARGING & STARTING SYSTEM

Starter Relay
1. Inspect starter relay for cracks, loose terminals, or loose terminal lead connections.
2. Connect ohm meter between starter relay terminals as shown.
3. Connect BLACK wire lead of starter relay to negative (–) terminal of 12 volt battery.
4. Connect BROWN/WHITE wire lead of starter relay to positive (+) terminal of 12 volt bat-
tery.
5. Replace starter relay if no continuity is found.

+ –

– +

b
c

d
a

8360

a - Ohm Meter Test Lead - BLACK

b - Ohm Meter Test Lead - RED
c - Starter Relay Wire Lead - BROWN/WHITE
d - Starter Relay Wire Lead - BLACK
e - 12 Volt Battery

Page 2B-20 90-881980R1 NOVEMBER 2001

 CHARGING & STARTING SYSTEM

Starter Motor
Removal
WARNING
Always disconnect the battery and remove spark plug leads from spark plugs be-
fore working on motor.
1. Disconnect battery leads. Remove electrical component cover. Disconnect RED wires
from starter solenoid. Disconnect BLACK (negative) battery cable from starter. Discon-
nect BROWN/WHITE wire from slave solenoid.
2. Remove 3 screws. Remove starter.

d
a
b

58672
58566

a - Screws (3) M8 x 45 mm
b - Positive (RED) Starter Motor Lead (Battery)
c - Negative (BLACK) Starter Motor Lead
d - BROWN/WHITE

90-881980R1 NOVEMBER 2001 Page 2B-21

CHARGING & STARTING SYSTEM

Disassembly
1. Place starter in vise.
2. Rotate pinion gear clip opening towards front. Using a screwdriver push down on pinion
gear. Using a hammer tap pinion gear stopper until pinion gear clip is protruded enough
to pry out with a small screwdriver.

a b
57637
a - Pinion Gear
b - Pinion Gear Stopper

3. Loosen nut to disconnect spade connector on start solenoid from starter motor.
4. Remove 2 screws to separate start solenoid from starter motor.

a - Spade Connector
b - Screws (2) M6 x 52 mm

Page 2B-22 90-881980R1 NOVEMBER 2001

 CHARGING & STARTING SYSTEM

5. Remove 2 through screws from commutator end cap to separate commutator from gear
end.
6. Remove 2 screws from end cap to separate end cap from commutator.

b a

a - Thru Screws (2) M6 x 120 mm

b - Commutator End Cap Screws (2) M4 x 14 mm

7. Pull commutator along with grommet and brush assembly from end cap.
8. Using a suitable punch, tap plate from brush holder assembly.
9. Pull brush assembly from commutator.

57621

a - Plate

10. For pinion gear disassembly refer to exploded view.

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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 0.374 in. (9.5 mm) 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. Measure commutator undercut.
• Out of specification - replace.

a - Undercut
Commutator Undercut Limit
0.008 in. (0.2 mm)

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. Armature inspection.
• Clean with 600 grit sandpaper.

Page 2B-24 90-881980R1 NOVEMBER 2001

 CHARGING & STARTING SYSTEM

11. Measure commutator diameter.

• Out of specification - replace.

Commutator Diameter Limit

1.10 in. (28.0 mm)

12. 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.
13. Clean out the copper or brush dust from slots between the commutator bars.
14. Check the armature for shorts and ground. See “TESTING”.

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CHARGING & STARTING SYSTEM

Testing
ARMATURE TEST FOR GROUND
1. Set ohmmeter to (R x 1 scale).
2. To test commutator segments, place leads as shown. Should have continuity. If not
replace.
3. To test armature core, place leads as shown. Should have no continuity. If continuity ex-
ists, replace armature.
4. To test armature shaft, place leads as shown. Should have no continuity. If continuity
exists, replace armature.
c

a
b

a - Commutator Test c - Armature Shaft Test

b - Armature Test

BRUSH HOLDER INSPECTION

1. Measure brush length. If out of specification, replace brushes.

Brush Length Limit

0.374 in. (9.5 mm)

2. Set ohmmeter to (R x 1 scale).

NOTE: Only positive brushes 1 and 2 can be replaced. If negative brushes need to be re-
placed, then the entire brush holder assembly must be replaced.
3. Place leads on one positive brush and one negative brush. Should have no continuity.
If so, replace brushes. Repeat this procedure on the other brushes. Should have no con-
tinuity. If so replace brushes.

1 b

a - Negative (–) Brushes b - Positive (+) Brushes

Page 2B-26 90-881980R1 NOVEMBER 2001

 CHARGING & STARTING SYSTEM

Reassembly
1. Using special tool (91-875216) slide brush assembly over tool as shown. Slide brush
holder assembly onto commutator.
2. Replace plate onto armature end shaft by tapping with a hammer.
b d

a
57647

57635

91-875216 c

a - Brush Holder Tool (91-875216)

b - Brush Assembly
c - Plate
d - Threaded Holes
3. Slide armature assembly into end cap.
4. Secure armature assembly with 2 screws.
NOTE: Make sure thrust plate is installed inside cover.
NOTE: Make sure plate is aligned with threaded holes as shown above. Use punch to align
holes.

95
a
b
c

95 2-4-C with Teflon

a - Thrust Plate
b - End Cap
c - Screws (2) M4 x 16
5. Install armature stator cover over armature.

b
a

57900

a - Armature Stator Cover

b - End Cap

90-881980R1 NOVEMBER 2001 Page 2B-27

CHARGING & STARTING SYSTEM

6. Install lever into pinion shaft as shown.

7. Insert pinion shaft into top cover making sure it is seated properly.
8. Install bracket cover as shown.

57901
c

a - Lever
b - Pinion Shaft
c - Bracket Cover

9. Align marks and insert armature shaft assembly into top cover.
10. Secure with 2 through screws. Torque screws to specified torque.

b
b
57902
57636

a - Alignment Marks
b - Through Screws (2) M6 x 120
Starter Through Screw Torque
70 lb-in. (8 Nm)

Page 2B-28 90-881980R1 NOVEMBER 2001

 CHARGING & STARTING SYSTEM

11. Install starter solenoid to starter making sure grommet is in place and lever spring is in
proper holes of dust cover plate.
12. Slide lever into starter solenoid assembly shaft hole while inserting spring below lever
as shown.
13. Secure solenoid with 2 screws. Tighten to specified torque.

f
a c e

f
b
d
57626

a - Spring e - Lever
b - Dust Cover Plate Holes f - Shaft Hole
c - Screw M4 x 20 g - Solenoid Screws (2) M6 x 52
d - Grommet
Starter Solenoid Screw Torque
70 lb-in. (8 Nm)

14. Connect spade connector on start solenoid.

a
b

a - Spade Connector
b - Nut
Terminal Nut Torque
78 lb-in. (9 Nm)

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CHARGING & STARTING SYSTEM

15. Lubricate helix threads and drive end cap bushing with SAE 10W oil.
16. Install the spring, pinion and pinion stopper onto starter shaft.
17. Place circlip into groove on shaft.
18. Press the pinion stopper over the circlip.
IMPORTANT: Make sure the circlip fits tightly into pinion stopper.

a b

c
b d

d
c

a - Circlip
b - Pinion Stopper
c - Pinion
d - Spring

Page 2B-30 90-881980R1 NOVEMBER 2001

 CHARGING & STARTING SYSTEM

Installation
1. Secure RED leads to starter solenoid with nut.

58671
a - Nut
Terminal Nut Torque
70 lb-in. (8 Nm)

2. Install terminal cover over nut.

58669
a - Cover

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CHARGING & STARTING SYSTEM

3. Secure starter motor to cylinder block with 3 screws.

58566
a - Screws
Starter Motor Mounting Screw Torque
13 lb-ft (18 Nm)

4. Secure BRN/WHT lead to slave solenoid.

58672
a - BRN/WHT Lead
b - Slave Solenoid

Page 2B-32 90-881980R1 NOVEMBER 2001

 CHARGING & STARTING SYSTEM

5. Connect RED positive battery cable to starter solenoid.

58566
a - Positive (RED) Battery Cable
b - Starter Solenoid
c - Negative (BLACK) Battery Cable
Positive Battery Terminal Nut Torque
70 lb-in. (8 Nm)
Negative Battery Terminal Screw Torque*
70 lb-in. (8 Nm)

6. Reinstall electrical cover.

7. Reconnect battery cables to battery.
* If removed.

90-881980R1 NOVEMBER 2001 Page 2B-33