Isuzu KB P190. Manual — part 403

6D-24 ENGINE ELECTRICAL (4JK1/4JJ1)

Reassembly

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Reassembly Steps

1. Magnetic Switch Assembly

2. Magnetic

Switch

3. Dust

Cover

4. Plunger

5. Torsion

Spring

6. Shift

Lever

7. Gear

Case

8. Dust

Cover

9. Bolt

10. Pinion Assembly

11. Clutch

12. Pinion Shaft

13. Return Spring

14. Pinion Stopper

15. Pinion Stopper Clip

16. Bearing Retainer

17. Bolt

18. Motor Assembly

19. Armature

20. Yoke

21. Brush Holder

22. Rear Cover

23. Screw

24. Through Bolt

25. Lead Wire

ENGINE ELECTRICAL (4JK1/4JJ1) 6D-25

Important Operations

1. Magnetic Switch Assembly

1) Attach the torsion spring to the hole in the

magnetic switch as illustrated.

2) Insert the shift lever into the plunger hole of the

magnetic switch.

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2. Gear Case

3. Dust Cover

1) Install the magnetic switch assembly in the

gear case.

2) Install the dust cover.

Dust Cover Bolt Torque

N

⋅m (kg⋅m/lb in)

8 (0.8 / 69)

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4. Pinion Assembly

Apply a coat of grease to the reduction gear and

install the pinion assembly to the armature shaft.

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5. Brush Holders

1) Install the brushes into the brush holder with

raising the spring end of the brush spring.

Take care not to damage the commutator face.

2) Install the brush holder with aligning the

peripheries of the yoke and the brush holder.

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6. Through Bolt

Install the through bolts in the rear cover and

tighten them to the specified torque.

Through Bolt Torque

N

⋅m (kg⋅m/lb in)

8.1 (0.83 / 69.7)

6D-26 ENGINE ELECTRICAL (4JK1/4JJ1)

065RY00044

7. Lead Wire

Connect the lead wire in the magnetic switch and

tighten the terminal nut to the specified torque.

Lead Wire Terminal Nut Torque

N

⋅m (kg⋅m/lb in)

8.6 (0.88 / 74.9)

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Inspection After Assembly

Use a vernier caliper to measure the pinion shaft thrust
play.

The pinion shaft thrust play is equal to the pinion shaft
end and pinion stopper clearance.

Pinion Shaft Thrust Play

mm (in)

0.1 – 2.0 (0.004 – 0.078)

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ENGINE ELECTRICAL (4JK1/4JJ1) 6D-27

Magnetic Switch

The following tests must be performed with the starter
motor fully assembled.

The yoke lead wire must be disconnected from the “M”
terminal.

To prevent coil burning, complete each test as quickly
as possible (within three to five seconds).

Temporarily connect the solenoid switch between the
clutch and the housing and run the following test.
Complete each test within three to five seconds.

1. Pull-in Test

Connect the battery negative terminal with the

solenoid switch body and the M terminal. When

current is applied to the S terminal from the battery

positive terminal, the pinion should flutter.

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2. Hold-in Maintenance Test

Disconnect the lead at the M terminal. The pinion

should continue to flutter.

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3. Return Test

Disconnect the battery positive lead at the S

terminal.

The pinion should return to its home position.

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