Mitsubishi Evolution X. Manual — part 244
STARTING SYSTEM
TSB Revision
ENGINE ELECTRICAL
16-29
MAGNETIC SWITCH HOLD-IN TEST
AKX01245
B
M
S
Battery
Starter
motor
Wire
AF
1. Disconnect the field coil wire from the M-terminal of the
magnetic switch.
CAUTION
This test must be performed quickly (in less than 10 sec-
onds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal and body.
3. Manually pull out the pinion as far as the pinion stopper
position.
4. If the pinion remains out, everything is operating properly. If
the pinion moves in, the hold-in circuit is open. Replace the
magnetic switch.
.
FREE RUNNING TEST
AKX01247
S
M
B
Ammeter
Carbon-pile
rheostat
Battery
Starter
motor
Voltmeter
AF
A
V
1. Place the starter motor in a vise equipped with soft jaws and
connect a fully-charged 12-volt battery to the starter motor
as follows:
2. Connect a test ammeter (100-ampere scale) and carbon pile
rheostat in series between the positive battery terminal and
starter motor terminal.
3. Connect a voltmeter (15-volt scale) across the starter motor.
4. Rotate carbon pile to full-resistance position.
5. Connect the battery cable from the negative battery terminal
to the starter motor body.
6. Adjust the rheostat until the battery positive voltage shown
by the voltmeter is 11 V.
7. Confirm that the maximum amperage is within the
specifications and that the starter motor turns smoothly and
freely.
Current: maximum 90 Amps
.
MAGNETIC SWITCH RETURN TEST
AKX01249
B
M
S
Battery
Starter
motor
Wire
AF
1. Disconnect the field coil wire from the M-terminal of the
magnetic switch.
CAUTION
This test must be performed quickly (in less than 10 sec-
onds) to prevent the coil from burning.
2. Connect a 12-volt battery between the M-terminal and body.
WARNING
Be careful not to get your fingers caught when pulling
out the pinion.
3. Pull the pinion out and release. If the pinion quickly returns
to its original position, everything is operating properly. If it
doesn't, replace the magnetic switch.
STARTING SYSTEM
TSB Revision
ENGINE ELECTRICAL
16-30
DISASSEMBLY AND ASSEMBLY
M1162001200611
AK704430 AB
2
16
17
18
19
15
13
12
20
4
14
11
1
5
6
8
7
9
10
3
6.1 ± 1.0 N·m
54 ± 8 in-lb
3.4 ± 1.0 N·m
30 ± 8 in-lb
5.8 ± 1.6 N·m
52 ± 13 in-lb
DISASSEMBLY STEPS
1. Screw
<<
A>>
2. Magnetic switch
3. Screw
4. Bolt
5. Rear bracket
6. Brush holder
7. Rear bearing
8. Armature
9. Yoke assembly
10. Packing A
11. Packing B
12. Plate
13. Planetary gear
14. Lever
<<
B>> >>A
<< 15. Snap ring
<<
B>> >>A
<< 16. Stop ring
17. Overrunning clutch
18. Internal gear
19. Planetary gear shaft
20. Front bracket
DISASSEMBLY STEPS
STARTING SYSTEM
TSB Revision
ENGINE ELECTRICAL
16-31
DISASSEMBLY SERVICE POINTS
.
<<A>> MAGNETIC SWITCH REMOVAL
AK301505AG
Magnetic
stitch
B terminal
S terminal
M terminal
Field coil
lead
CAUTION
Do not clamp the yoke assembly with a vise.
Disconnect the lead from the M terminal of the magnetic switch.
.
<<B>> SNAP RING / STOP RING REMOVAL
AK304685
Socket wrench
Stop ring
Pinion gear
Overrunning
clutch
AF
1. Apply a long socket wrench of an appropriate size to the
stop ring and strike the wrench to drive out the stop ring
toward the pinion gear side.
AK304686
Snap ring pliers
Snap ring
Pinion gear
Overrunning
clutch
AF
2. Remove the snap ring with snap ring pliers, then remove the
stop ring and overrunning clutch.
STARTER MOTOR PARTS CLEANING
.
1. Never clean in a solvent such starter motor parts as the
magnetic switch, brush holder, and armature. If they are
soaked in a solvent, their insulation could be impaired.
When these parts require cleaning, wipe off contamination
with cloth.
2. Never soak the drive unit in a solvent. If it is washed in a
solvent, the grease having been packed in the overrunning
clutch at the factory will be washed out. Wipe the drive unit
with cloth if it requires cleaning.
STARTING SYSTEM
TSB Revision
ENGINE ELECTRICAL
16-32
REASSEMBLY SERVICE POINTS
.
>>A<< STOP RING / SNAP RING INSTALLATION
AK304687
Overrunning
clutch
Stop ring
Snap ring
Stop ring
AF
Use a suitable puller to pull the stop ring until it gets over the
snap ring.
INSPECTION
M1162001300470
.
COMMUTATOR CHECK
AK304688
1. Place the armature on a pair of V-blocks, and check the
deflection by using a dial gauge.
Standard value: 0.05 mm (0.002 inch)
Limit: 0.10 mm (0.004 inch)
AK304689
2. Check the outer diameter of the commutator.
Standard value: 29.4 mm (1.16 inch)
Minimum limit: 28.8 mm (1.13 inch)
AK304690
Segment
Undercut
Mica
AF
3. Check the depth of the undercut between segments.
Standard value: 0.5 mm (0.02 inch)
Minimum limit: 0.2 mm (0.01 inch)
.
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