Mitsubishi Outlander XL. Manual — part 446

ZK602533 AA00

1

2

18

19

10

11

12

13

14

15 16

17

20

3

4

5

6

7

8

9

DISASSEMBLY STEPS

1.

SCREW

2.

MAGNETIC SWITCH

3.

SCREW

4.

SCREW

5.

REAR BRACKET

6.

BRUSH

7.

REAR BEARING

8.

ARMATURE

9.

YOKE ASSEMBLY

10
.

PACKING A

11
.

PACKING B

12
.

PLATE

13
.

PLANETARY GEAR

DISASSEMBLY STEPS

14
.

LEVER

<<A>>

>>A<< 15

.

SNAP RING

<<A>>

>>A<< 16

.

STOP RING

17
.

OVERRUNNING CLUTCH

18
.

INTERNAL GEAR

19
.

PLANETARY GEAR HOLDER

20
.

FRONT BRACKET

STARTING SYSTEM

16b-9

STARTER MOTOR ASSEMBLY

DISASSEMBLY SERVICE POINTS

<<A>> SNAP RING AND STOP RING REMOVAL

ZK602489AA00

Overrunnning
clutch

Pinion gear

Socket

Stop ring

1.

Press a long socket wrench of appropriate size to the stop ring.
Then tap the socket wrench to remove the stop ring to the
pinion gear side.

ZK602490AA00

Snap-ring pliers

Snap ring

Pinion gear

Overrunning
clutch

2.

After removing the snap ring (by using snap-ring pliers),
remove the stop ring and the overrunning clutch.

STARTER MOTOR PART CLEANING

1.

Do not immerse parts in cleaning solvent. Immersing the yoke
and field coil assembly and/or armature will damage
insulation. Wipe these parts with a shop towel only.

2.

Do not immerse the drive unit in cleaning solvent. Overrunning
clutch is pre-lubricated at the factory and solvent will wash
lubrication from the clutch.

3.

The drive unit may be cleaned with a brush moistened with
cleaning solvent and wiped dry with a shop towel.

16b-10

STARTING SYSTEM

STARTER MOTOR ASSEMBLY

ASSEMBLY SERVICE POINT

>>A<< STOP RING AND SNAP RING INSTALLATION

ZK602491AA00

Stop ring

Snap ring

Overrunning
clutch

Stop ring

Using a suitable pulling tool, pull the overrunning clutch stop ring
over the snap ring.

INSPECTION

M11602000013USA0000010000

COMMUTATOR CHECK

ZK602090AA00

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: 0.1 mm (0.004 inch)

ZK602091AA00

2.

Check the outer diameter of the commutator.

Standard value: 29.4 mm (1.16 inches)
Minimum limit: 28.8 mm (1.13 inches)

ZK602092

Segment

Undercut

Mica

0000

3.

Check the depth of the undercut between segments.

Standard value: 0.5 mm (0.02 inch)
Minimum limit: 0.2 mm (0.008 inch)

STARTING SYSTEM

16b-11

STARTER MOTOR ASSEMBLY

BRUSH CHECK

ZK602534

Limit length

AA00

1.

Check the brush for roughness of the surface that contacts the
commutator and check the brush length. Replace the brush
holder if this measurement exceeds the limit.

Minimum limit:
7.0 mm (0.28 inch)

2.

If the contacting surface has been corrected or the brush has
been replaced, correct the contacting surface by winding
sandpaper around the commutator.

OVERRUNNING CLUTCH CHECK

ZK602096

Free

Lock

0000

1.

While holding the clutch housing, rotate the pinion. The drive
pinion should rotate smoothly in one direction, but should not
rotate in the opposite direction. If the clutch does not function
properly, replace the overrunning clutch assembly.

2.

Inspect the pinion for wear or burrs. If the pinion is worn or
burred, replace the overrunning clutch assembly. If the pinion
is damaged, also inspect the ring gear for wear or burrs.

FRONT AND REAR BRACKET BUSHING CHECK
Inspect the bushing for wear or burrs. If the bushing is worn or
burred, replace the front bracket assembly or rear bracket
assembly.

ARMATURE CHECK

ZK602099

Growler

0000

1.

Check that the armature coil is not grounded.

2.

Place the armature in a growler.

3.

Hold a thin steel blade parallel and just above while rotating
the armature slowly in the growler. A shorted armature will
cause a blade to vibrate and be attracted to the core. Replace
the shorted armature.

16b-12

STARTING SYSTEM

STARTER MOTOR ASSEMBLY