Mitsubishi Lancer. Manual — part 208
STARTING SYSTEM
ENGINE ELECTRICAL
16-24
MAGNETIC SWITCH HOLD-IN TEST
AK300650 AB
<4G1>
S
B
M
Wire
Battery
Starter
motor
AKX01244
<4G6>
S
B
M
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 seconds) 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 in order. If
the pinion moves in, the hold-in circuit is open.
Replace the magnetic switch.
FREE RUNNING TEST
AK300651AB
<4G1>
S
A
M
V
B
Carbon-pile rheostat
Battery
Voltmeter
Ammeter
Starter
motor
AKX01246
<4G6>
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 battery
(+) terminal and starter motor terminal.
3. Connect a voltmeter (15-volt scale) across the
starter motor.
4. Rotate the rheostat to full-resistance position.
5. Connect the battery cable from the battery (-)
terminal to the starter motor body.
6. Adjust the rheostat until the battery voltage shown
on 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:
<4G1> maximum 95 Amps
<4G6> maximum 90 Amps
STARTING SYSTEM
ENGINE ELECTRICAL
16-25
MAGNETIC SWITCH RETURN TEST
AK300652 AB
<4G1>
S
B
M
Wire
Battery
Starter
motor
AKX01248
<4G6>
S
B
M
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 seconds) 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
ENGINE ELECTRICAL
16-26
DISASSEMBLY AND REASSEMBLY
M1162001200202
AK201881
14
12
11
20
1
15
16
17
18
19
13
10
2
4
3
5
7
6
8
9
AG
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 SERVICE POINTS
<<A>> MAGNETIC SWITCH REMOVAL
AK201882
B terminal
M terminal
S terminal
AC
CAUTION
Do not clamp the yoke assembly with a vise.
Disconnect the lead from the M terminal of the mag-
netic switch.
STARTING SYSTEM
ENGINE ELECTRICAL
16-27
<<B>> SNAP RING/STOP RING REMOVAL
AK100883AC
Socket wrench
Stop ring
Pinion Gear
Overrunning
clutch
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.
AK202791
Snap ring
pliers
Snap ring
Pinion gear
Overrunning
clutch
AB
2. Remove the snap ring with snap ring pliers, then
remove the stop ring and overrunning clutch.
STARTER MOTOR PARTS CLEANING
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.
1. 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.
REASSEMBLY SERVICE POINTS
>>A<< STOP RING/SNAP RING INSTAL-
LATION
AK202911
Overrunning
clutch
Stop ring
Snap ring
Stop ring
AB
Use a suitable puller to pull the stop ring until it gets
over the snap ring.
INSPECTION
M1162001300157
COMM.U.T.ATOR
AK202712
1. Support the armature with a pair of V block and
turn it to measure the runout of the surface not
rubbed by the brushes using a dial gauge.
Standard value: 0.05 mm or less
Limit: 0.1 mm
AK202715
2. Measure the diameter of the commutator.
Standard value: 29.4 mm
Limit: 28.8 mm
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