SECTION 6D1-2 - STARTING SYSTEM -

V6 ENGINE & V6 SUPERCHARGED

CAUTION:

This vehicle will be equipped with a Supplemental Restraint System (SRS). A SRS will consist of either

seat belt pre-tensioners and a driver’s air bag, seat belt pre-tensioners and driver’s and front

passenger’s air bags or seat belt pre-tensioners, driver’s and front passenger’s air bags and left and

right-hand side air bags. Refer to SAFETY PRECAUTIONS, Section 12M Supplemental Restraint System

in the VT Series I Service Information before performing any service operation on, or around any SRS

components, the steering mechanism or wiring. Failure to follow the SAFETY PRECAUTIONS could

result in SRS deployment, resulting in possible personal injury or unnecessary SRS system repairs.

CAUTION:

This vehicle may be equipped with LPG (Liquefied Petroleum Gas). In the interests of safety, the LPG

fuel system should be isolated by turning 'OFF' the manual service valve and then draining the LPG

service lines, before any service work is carried out on the vehicle. Refer to the LPG leaflet included with

the Owner's Handbook for details or the appropriate Section of this Service Inforamation CD for more

specific servicing information.

1. GENERAL INFORMATION

A Bosch DV, four-pole, four-brush starter motor is fitted to the VT Series II models, and is illustrated in

Fig. 6D1-2-1.

Figure 6D1-2-1

1.1 GENERAL DESCRIPTION

The starting system comprises the battery, starter

motor, ignition switch, neutral/back-up switch

(vehicles with automatic transmission), theft

deterrent engine crank inhibitor (function of theft

deterrent system) and related electrical wiring.

The starter motor is a series parallel wound, four

pole, four brush type with a planetary drive train.

The arm ature shaft is supported at each end by oil

absorbent sintered metal bushes pressed into the

commutator end cover and the inside of the

planetary drive shaft.

The planetary drive train comprises a ring gear

(made from a high-grade polyamide compound

with mineral additives) with gear teeth on the inside

diameter, three planetary gear wheels, a planetary

drive shaft and a cover plate. When assembled, the

planetary drive shaft, which is flanged at one end

with three shafts machined onto the flange, is

positioned on a sintered metal bus h in the ring gear

and secured by a washer and retaining clip. The

three gear wheels, each mounted on needle roller

bearings, are fitted onto the shafts on the flange of

the planetary drive shaft where they mesh with the

internal teeth of the ring gear. A lubricant

impregnated sintered metal bush is fitted into the

recess in the flanged end of the planetary drive

shaft to provide a mounting for the end of the

armature. The cover plate is positioned and

secured over the gear end of the assembly.

The drive assembly is installed onto the planetary

drive shaft, m eshed with the gear on the drive shaft

and secured to the shaft by a stop ring and ring

retainer. The combined assembly is installed into

position in the starter m otor drive end hous ing. The

planetary drive shaft is supported by a sintered

metal bush in the drive end housing, while the ring

gear is keyed to the drive end housing, providing

positive and sec ure m ounting of the dr ive s haft and

drive assembly.

When the starter motor is assembled, the teeth of

the gear on the armatur e shaft m esh with the teeth

on the three planetary gears wheels. When the

starter motor is operated, drive from the armature

causes the planetary gear wheels to rotate, caus ing

the gear wheels to revolve around the inner

diameter of the ring gear. This action causes the

planetary drive shaft to rotate and impart drive into

the drive assembly. During operation of the starter

motor the armature r otates the drive assem bly at a

reduced speed of approximately 3.36:1.

The s intered m etal bearings require lubric ation only

at the time of an overhaul.

Figure 6D1-2-2

The four brushes are supported by the brush holder which is retained to the commutator end cover by screws.

Two brushes ar e grounded to the f ield c oil hous ing, and two are insulated f r om the housing and c onnec ted to the

field coils. The field coils are held in place by the pole shoes which are attached to the f ield coil housing by large

diameter screws. The field coils are connected to an insulated terminal on the field coil housing through which

current is supplied to the starter motor from the solenoid switch.

On the drive end housing, a plas tic for k with plastic bearing bloc k is used to engage the drive as sembly with the

flexplate/ring gear.

The drive assembly transmits cranking torque to the flexplate/ring gear. To prevent the armature from being

driven at exces sive speed by the engine, an internal clutch allows the drive ass embly pinion gear to rotate f reely

in relation to the planetary shaft and armature when the engine begins to operate.

T6D12001

32 33 34 35 36

Figure 6D1-2-3

1 Solenoid switch to drive end 13 Drive lever bearing 26 Brush holder and negative

housing mounting screws 14 Sealing rubber brushes

2 Plunger 15 Clip 27 Brush

3 Return spring 16 Washer 28 Brush holder spring

4 Solenoid switch 17 Bush 29 Thrust washer

5 ‘M’ terminal nut and washer 18 Planetary drive shaft 30 Commutator end cover

6 Drive end housing bush 19 Commutator front cover bush 31 Through bolt (standard)

7 Drive end housing 20 Cover plate 32 Commutator end cover bush

8 Stop ring 21 Field coil housing 33 Adjustment washers

9 Stop ring retainer 22 Field coil pole side screws 34 Horse shoe clip

10 Drive assembly bush 23 Pole shoe 35 Dust cover seal

11 Drive assembly 24 Field coil and positive brushes 36 Felt pad

12 Fork lever 25 Armature 37 Dust cover

2. SERVICE OPERATIONS

2.1 PERFORMANCE TESTING

The following tests involve the starter motor being

removed from the vehicle, refer to 2.2 STARTER

MOTOR in this Section.

SOLENOID SWITCH TESTS

Pull-in Test

1. Remove nut and washer from solenoid switch

short threaded terminal ('M' terminal). Remove

field coil braided cable and terminal from

threaded terminal.

2. Using suitable test leads and 12 volt battery,

connect as shown in Fig. 6D1-2-4. Check that

drive assembly moves outward.

If drive assembly does not move, replace

solenoid switch as described in this Section.

Figure 6D1-2-4

Hold-in Test

1. With battery connections to starter motor and

solenoid switch as shown for Pull-in Test,

disconnect negative lead from solenoid switch

short threaded terminal ('M' terminal).

2. Check that drive assembly remains outward.

If drive assembly returns inward, replace

solenoid switch as described in this Section.

Figure 6D1-2-5

Drive Assembly Return

1. With battery and connections to starter motor

and solenoid switch as at end of Hold-in Test,

disconnect negative lead from drive end

housing.

2. Check that drive assembly returns inward.

If drive assembly does not return, replace

solenoid switch as described in this Section.

Figure 6D1-2-6

NO LOAD TEST

The drive assembly pinion should be checked for

freedom of operation by turning it on the planetary

drive shaft. The planetary drive and armature

should be checked for f reedom of r otation by prying

the drive assembly pinion with a screwdriver. If the

planetary drive and armature do not rotate freely,

the starter motor should be disassembled

immediately. However, if the planetary drive and

armature do rotate freely, the starter motor should

be given a No Load test before disassembly.

Clamp starter motor securely to a test bench and

make connections as shown. Close the switch and

compare the rpm, current and voltage readings

with the following specifications.

If the No Load test indicates that the starter motor

is defective, refer to 3 DIAGNOSIS in this Section

for probable cause of starter motor fault.

Figure 6D1-2-7

STARTER MOTOR SPEED

(ARMATURE RPM) 5300 rpm

STARTER MOTOR CURRENT 125 amps

TERMINAL VOLTAGE 11.5 volts

2.2 STARTER MOTOR

REMOVE

1. Disconnect battery earth lead.

2. Jack up front of vehicle and support on safety

stands. For location of jacking locations, refer

to Section 0A GENERAL INFORMATION in

the VT Series I Service Information.

3. Remove starter motor to cylinder block

mounting bolts.

Lower starter motor and out as far as possible

so as to gain access to wiring harness

connections at starter motor solenoid switch.

Figure 6D1-2-8

4. Pull wiring harness connector from solenoid

switch '50' terminal.

5. Remove nut, washer and battery lead from

solenoid switch '30' (B+) terminal.

Figure 6D1-2-9

6. Withdraw starter motor.

Figure 6D1-2-10

REINSTALL

Installation of the starter motor is the reverse of

removal procedures, noting the following points:

1. Ensure that all fasteners are tightened to the

correct torque specification.

STAR TER MOTOR TO

CYLINDER BLOCK

MOUNTING BOLT

TORQUE SPECIFICATION 40 – 60 Nm

STARTER MOTOR '30' (B+)

TERMINAL NUT

TORQUE SPECIFICATION 9.8 – 11.3 Nm

2. Check starter motor operation.

DISASSEMBLE

1. Remove nut and washer from solenoid switch

short threaded terminal ('M' terminal). Remove

field coil braided cable and terminal from

threaded terminal.

Figure 6D1-2-11

2. Scribe an aligning mark on drive end housing

and solenoid switch housing as an aid for

reassembly.

Remove the three solenoid switch to drive end

housing mounting screws.

NOTE: It m ay be necessary to loosen the mounting

screws using an impact driver. Ensure to only

lightly tap on the im pact driver so as not to dam age

the drive end housing.

Figure 6D1-2-12

3. Pull solenoid switch from drive end housing,

taking care not to lose the plunger return

spring. (Plunger will slide out from solenoid

switch and remain attached to drive assembly

fork lever).

4. Remove solenoid switch plunger by lifting up

and then unhooking front from drive assembly

fork lever.

Figure 6D1-2-13

5. Scribe an aligning mark on drive end housing,

field coil housing and comm u tator end c over as

an aid for reassembly.

6. Loosen and remove the two through bolts

securing the commutator end cover and field

coil housing to the drive end housing.

Figure 6D1-2-14

7. Keeping the sealing rubber seated in the drive

end housing, remove the commutator end

cover, field coil housing and armature an

assembly from the drive end housing.

Figure 6D1-2-15

8. Remove the screws securing the dust cover to

the commutator end cover and brush holder.

Remove horse shoe clip and adjustment

washer/s from commutator end of armature.

Figure 6D1-2-16

9. While holding field coil braided cable seal to

the field coil housing, pull commutator end

cover from field coil housing.

Figure 6D1-2-17

10. Carefully bend back all the brush holder spring

retaining tags, remove all springs and the

positive brushes. Remove the brush holder

from the armature's commutator.

Figure 6D1-2-18

11. Remove the armature from the field coil

housing. Remove the armature to commutator

end cover thrust washer. (The washer may

either be on the end of the armature or

attached to the inside of the commutator end

cover).

Figure 6D1-2-19

12. Remove the sealing rubber from drive end

housing, noting how it is installed.

13. Rem ove the drive ass embly with fork lever and

planetary drive assembly from the drive end

housing.

14. Remove fork lever from drive assembly by

spreading fork lever arms and disengaging

from drive assembly pivots.

Figure 6D1-2-20

15. Clamp the end of the planetary drive shaft in a

vice fitted with soft jaws. Prise the stop ring

retainer towards the drive assembly using two

screwdriver s pivoting on vice jaws and levering

against stop ring retainer.

As an alternative, use Bosch Tool Nos. KDAL

5047 and KDAL 5028.

16. Remove planetary drive shaft and drive

assembly from the vice.

17. Using a pair of circlip pliers, expand the stop

ring and slide it from the planetary drive shaft,

taking care not to scratch or damage the

planetary drive shaft.

18. Before attempting to remove the drive

assembly, remove any burrs on the planetary

drive shaft, particularly in the area of the stop

ring groove using a fine file. This step is

necessa ry so as to prevent dam aging the drive

assembly to planetary drive shaft bushing when

removing the drive assembly.

Slide the stop ring retainer and drive assem bly

from the planetary drive shaft.

Figure 6D1-2-21

19. Prise the cover plate from the ring gear.

Figure 6D1-2-22

20. Remove planetary drive shaft to ring gear

retaining clip and washer.

Figure 6D1-2-23

21. Carefully push the planetary drive shaft (1)

from ring gear (2) ensuring that gear teeth on

planetary drive shaft do not damage bush in

ring gear, and separate components.

T6D12024

Figure 6D1-2-24

CLEANING AND INSPECTION

With the starter m otor completely disassembled, all

components should be cleaned and thoroughly

inspected.

W ash all c omponents exc luding the armature, f ield

coils, brushes, solenoid switch and drive assembly

in a suitable cleaning agent. Clean these

com ponents with clean shop rags and com pres sed

air.

CAUTION: Do not clean armature or field coils

with cleaning solvent as damage to the

insulation could occur.

Washing the drive assembly in solvent will

wash out all the lubricant, causing the drive

assembly to slip.

CAUTION: Clean all parts other than those

previously nominated using a non volatile or

low inflammable agents in a well ventilated

area. It is important that all parts are thoroughly

dried before assembly, taking care not to

breath in any vapours. Observe the safety

regulations and precautions issued by the

manufacturer of the cleaning agent in use.

COMPONENT CHECKING

Field Coils

1. Connect a 12 volt powered DC test lamp

between field coil braided cable terminal and a

positive brush. If the field coil circuit is

serviceable, the lamp will illuminate to indicate

continuity.

Repeat the procedure on the other positive

brush.

Figure 6D1-2-25

2. Ensure brushes are not touching the field coil

housing. Test the field coils for short circuits to

earth using an insulation tes ter with a m inim um

AC voltage of 40 volts.

NOTE: An ohmmeter cannot be used to check the

field coils for short circuits to earth as the output

voltage from the ohmmeter does not place

sufficient 'stress' on the field coils to give an

accurate test result.

Figure 6D1-2-26

3. Visually inspect field coil windings for signs of

insulation breakdown and/or burns

(overheating). If this condition is present, the

field coil must be replaced as follows:

NOTE: This starter m otor us es an interlock ing joint

in the field coil housing, therefore care must be

exercis ed whenever clam ping the field coil hous ing

in a vice. Ensur e the vice is f itted with sof t j aws and

do not over tighten as it will distort the housing.

It is recommended that a mandrel having a

diameter of 52.8 + 0.2 – 0.1 mm x 30 mm long be

inserted inside the field coil housing, between the

field coil pole shoes. This step is necessary so as

to support the field coil housing in the vice whilst

the field coil pole shoe screws are removed.

a. Place mandrel inside field coil housing and

clamp the housing in a vice with soft jaws.

Figure 6D1-2-27

b. Using a Posidrive No. 3 bit, loosen and

remove the four field coil pole shoe screws.

Figure 6D1-2-28

c. Remove field coil housing from vice and

pull the field coil out from the brush end of

the housing complete with mandrel and

pole shoes. Separate mandrel, field coils

and pole shoes.

Figure 6D1-2-29

d. Insert the pole shoes into the new field coil

and place inside the field coil housing.

Install the pole shoe screw and leave finger

tight.

e. Insert mandrel inside field coil housing to

support pole shoes and clamp in vice with

soft jaws.

f. Tighten field coil pole shoe screws to the

correct torque specification.

FIELD COIL POLE

SHOE SCREW

TORQUE SPECIFICATION 25 Nm

g. Check field coils using insulation tester.

FIELD COIL RESISTANCE 1 Mohm

or greater

ARMATURE INSULATION TEST

Check armature insulation resistance to earth

using a 'meggar' or similar tester. A reading of 1

Mohm or greater should be expected.

Armature Short Circuit Test

Test armature for short circuits on a growler.

1. Place the armature on a growler and switch on

growler. Hold a hacksaw blade approximately

6 mm above armature core and rotate

armature.

2. If the hacksaw blade vibrates, undercut

between the comm utator segm ents (to a depth

of approximately 0.8 mm) using a suitable

small file, then check the armature again.

3. If hacksaw blade still vibrates, the armature is

short circuited and must be replaced.

Figure 6D1-2-30

Armature Continuity Test

An open circuit in the armature winding may

sometimes be detected by examining the

commutator for evidence of burnt or darkened

segments. A burnt or darkened commutator

segm ent is c aused by an arc for med every time the

segment connected to the open circuit winding

passes under the brush.

If a segment has been burnt or is darkened,

replace armature.

Test the armature for continuity on a growler.

1. Place the armature on a growler and switch on

growler.

2. Using a voltmeter, measure the voltage

induced in the armature windings by touching

probes onto two adjacent commutator

segments.

NOTE: To obtain maximum voltage reading,

choose two segments which are approximately

45 degrees from the top of the commutator.

3. Rotate the armature in the growler so that the

next two commutator segments are in the

sam e position as the previous two segm ents in

Step 2. Measure voltage across adjacent

commutator segments.

4. Repeat Step 3 until voltage reading across all

adjacent sets of commutator segments has

been measured.

The voltage reading across each adjacent pair

of commutator segments should be the same,

provided each adjacent set of segments are

positioned in the growler in the same location.

If a voltage reading across any adjacent set of

segments differs from the remainder, the

armature winding has an open circuit, and the

armature must be replaced.

Figure 6D1-2-31

Commutator Sur face

Check commutator and armature laminations for

out-of-round.

If the armature is otherwise satisfactory but

commutator is worn, burnt, out-of round, or has

high insulation between the segments, the

commutator should be machined.

If the out-of-round check on the armature

laminations is greater than the specified value,

replace the armature.

Figure 6D1-2-32

NOTE: Replace the armature if the commutator

diameter is below the dimension given in the

following chart.

When machining the arm a ture, it m ust not be held

by the laminations. The armature must be held at

the drive end and supported at the commutator

end bearing surface.

It is recom mended that the com mutator be turned

in two stages, that is pre-turning and finish turning. Figure 6D1-2-33

Finish cut the armature using a fine tool. The cut

should be no more than 0.03 mm. After turning,

polish surf ace if neces sary using 500 – 600 grade

emery cloth and then brush out the commutator

segment slots using a stiff brush.

Check the diameter of the commutator. If less

than the specified value, replace the armature.

Figure 6D1-2-34

Check depth of insulating mica from commutator

surface. If depth is less than 0.2 mm, undercut

using a file to a depth of 0.5 to 0.8 mm.

CAUTION: It is important to use dust

extrac tion when undercutting commutators.

After undercutting, carefully clean all dirt and

debris from commutator segment slots and lightly

polish commutator with fine emery cloth to r emove

any burrs lef t by the undercutting operation. Clean

commutator and armature thoroughly using

compressed air.

Figure 6D1-2-35

COMMUT ATOR MINI MUM

DIAMETER 31.2 mm

COMMUT ATOR MAXIMUM

PERMISSIBLE

OUT-OF-ROUND 0.1 mm

MAXIMUM PERMISSIBLE OUT-

OF-ROUND OF ARMATURE

LAMINATIONS 0.5 mm

Brushes

Check brush holder springs for breakage and

corrosion, replace as necessary.

Ensure that brus hes s lide smoothly in their holder s ,

brush connec tions are good and brushes are clean

and not chipped.

Check brush length. If any brush is below

specification, replace the complete brush set and

machine commutator if necessary.

If necessary, replace brushes as follows:

Figure 6D1-2-36

Positive Brushes

1. Cut the brush lead approximately 4 mm up

from the field coil connecting strap and discard

brush.

2. Clean the remains of brush lead on field coil

connecting strap and 'tin' the lead with 60/40

resin cored solder.

3. Hold the new brush lead in position on the pre-

tinned cut-off lead using a pair of pointed nose

pliers. Solder new brush lead to cut-off lead.

NOTE: When soldering the new brush lead into

place, ensure that the solder does not run up the

lead by capillary action. Should this happen, it will

make the lead too inflexible and not allow correct

brush movement and/or cause fouling during

reassembly.

Figure 6D1-2-37

Negative Brushes

1. Before removing the old brushes, special

attention must be paid to the direction of the

brushes in the way they are soldered to the

plate.

MINIMUM BRUSH

LENGTH 7 mm

2. Cut old brush lead off at lowest point of the

flexible braided section.

3. Clean remaining brush lead on brush holder.

'Tin' rem aining brush lead on brush holder with

60/40 resin cored solder.

Figure 6D1-2-38

3. Hold the new brush lead in position on the pre-

tinned cut-off lead using a pair of pointed nose

pliers, noting brush lead direction as per

Step 1. Solder new brush lead to cut-off lead.

NOTE: When soldering the new brush lead into

place, ensure that the solder does not run up the

lead by capillary action. Should this happen, it will

make the lead too inflexible and not allow correct

brush movement and/or cause fouling during

reassembly.

Figure 6D1-2-39

Brush Holder Assembly

Using an ohmmeter, check insulation between the

positive brush holders and the brush holder

assembly base. If continuity exists, replace holder

assembly.

Figure 6D1-2-40

Check continuity between negative brushes and

holder assembly base. If continuity does not exist,

replace the brush holder.

Check condition of the brush holder spring retaining

tags. If any tags are weak, broken or there is any

sign of fatigue from being bent back, replace the

brush holder assembly.

Figure 6D1-2-41

Drive Assembly Check

Inspect drive assembly pinion gear for burrs and

worn or chipped teeth.

Check the operation of the pinion. The pinion gear

should rotate free and smooth in relation to the

drive assembly pinion housing when turned in a

clockwise direction, but will not rotate when turned

in a counter-clockwise direction.

Replace the drive assembly if out of specification,

or if pinion gear is damaged or broken, inspect

flexplate/ring gear teeth and replace as necessary,

refer to Section 6A1-1 ENGINE MECHANICAL —

V6 ENGINE in the VT Series II Service Infromation.

Examine the pinion internal bush for wear or

scoring, if in any doubt, replace the drive assembly.

Inspect fork lever contact surfaces and pivots.

Replace fork lever if worn.

Figure 6D1-2-42

Bushes

Check the fit of the armature shaft in the commutator

end cover and the front end of the planetary drive

shaft in the drive end housing.

If bushes are excessively worn, the starter motor is

likely to operate inefficiently and/or the armature may

foul on the field coils.

To remove the bushes, support the commutator end

cover or drive end housing (as appropriate), and

carefully tap bush out using a suitable sized mandrel.

NOTE: If new bushes are to be installed, they must be

soaked in clean engine oil overnight. If time does not

permit over night soaking, oil can be forced into the

bush by placing a thumb over end of the bush and

filling the bush cavity with oil.

Using the other thumb over the opposite end of the

bush, press bush firmly compressing the oil between

thumbs until the oil is visible on the outer surfaces of

the bearing.

To ins tall new bushes, pres s or tap into pos ition with a

suitable shouldered mandrel.

Do not ream bushes after they have been installed as

the self-lubricating qualities of the bush will be

diminished.

Solenoid Switch Testing

Inspect the solenoid switch for any external

damage.

Install return s pring and plunger to s olenoid switch.

Depress plunger and releas e it. The plunger s hould

return quickly to its original position. If the plunger

sticks in the switch bore, replace solenoid switch

assembly.

Figure 6D1-2-43

Check the solenoid switch windings resistances

using an ohmmeter across the terminals nominated

in the following chart.

Figure 6D1-2-44

Replace solenoid switch if resistance readings are

not to specification

Figure 6D1-2-45

PULL-IN WINDING

RESISTANCE TERMINALS 50 AND M

HOLD-IN

WINDING

RESISTANCE

TERMINAL 50 AND

SOLENOID SWITCH

HOUSING

PULL-IN WINDING

RESISTANCE 0.248 – 0.281

ohms @ 20° C

HOLD-IN WINDING

RESISTANCE 1.16 – 1.30

ohms @ 20° C

Testing 'Pull-in' and 'Hold-in' Voltages

During the following solenoid switch 'pull-in' and

'hold-in' checks, the solenoid switch must be held

vertically, i.e. with the plunger uppermost. It is

recommended that a rubber band be fitted around

the plunger and solenoid switch housing to prevent

the plunger from flinging out during testing.

Using a power supply capable of supplying 30

amps, set the voltage to 3.0 volts. A battery and a

variable resistor may also be used.

Connect the solenoid to the power supply as shown

in Fig. 6D1-2-46.

Connect a 12 volt test lamp between solenoid

switch terminal '30' and +12 volt supply. Also,

connect a voltmeter between solenoid switch

terminal 50 and earth.

Fully press in solenoid plunger until test lamp

illuminates. Allow the plunger to spring out by

approximately 8 - 10 mm and hold in this position.

NOTE: The test duration for the following 'pull-in'

voltage check should be no more than two

seconds.

Slowly increase the voltage on terminal '50' until the

plunger pulls in, noting the voltmeter reading. At the

same time, the test lamp must be fully illuminated

(check of solenoid switch main contact continuity)

Voltage reading should be as specified in the

following chart.

Figure 6D1-2-46

Set the power supply to 12 volts and connect the

positive lead to solenoid switch terminal '50'.

Connect the negative lead to the solenoid switch

housing. Press the plunger in f ully. It should rem ain

held in by the solenoid's hold-in winding.

Decrease the voltage until the winding will no

longer hold the plunger, noting the voltmeter

reading.

Voltage reading should be as specified in the

following chart.

Press the plunger until the solenoid switch c ontacts

close (indicated by test lamp illuminating).

It should be possible to depress the plunger into

the solenoid switch housing a further 1 mm or

more. If less than 1 mm is achieved, the solenoid

switch must be replaced.

Figure 6D1-2-47

PULL-IN VOLTAGE TEST

SPECIFICATION 3.0 – 6.5

volts

HOLD-IN VOLTAGE TEST

SPECIFICATION 0.2 – 2.0

volts

A 24 volt supply is required for this test.

Attach positive supply lead to solenoid switch

terminal '30' (main battery supply input) and

negative lead to solenoid switch housing.

Press the plunger in fully and then release. The

plunger should return to its rest position by the

action of the return spring. If it does not, the

windings have interwinding short circuits.

W hen the solenoid s witch is connected in this way,

the windings are differentially compounded, that is

their fields are in opposition to each other.

At end of solenoid switch testing, remove rubber

band retaining the plunger and return spring in the

solenoid switch housing.

Figure 6D1-2-48

REASSEMBLE

Reassembly of the starter motor is the reverse of

the disassembly procedure, noting the following

points:

1. Lubricate drive end housing, commutator end

cover and drive assembly to planetary drive

bushes with clean engine oil.

2. Lightly coat helix on armature shaft, helix inside

drive assembly, inside of ring gear and

armature to commutator end cover thrust and

adjustment washers with Molybdenum

Disulphide grease. Pac k some gr ease inside of

commutator end cover dust cover.

3. Check arma ture end play by installing armatur e

to commutator end cover thrust washer,

assembling armature to commutator end cover.

Install adjustment washer and horse shoe clip.

Using feeler gauges, measure clearance

between adjustment washer and commutator

end cover. If necessary, adjust armature end

float to specification using adjustment washers

between commutator end cover and horse

shoe clip.

W hen end float is correct, remove commutator

end cover from armature.

Figure 6D1-2-49

ARMATURE END PLAY

SPECIFICATION 0.05 – 0.3 mm

4. To install the stop ring retainer over the stop

ring, clam p the front end of the planetary drive

shaft in a vice fitted with soft jaws. Slide the

stop ring retainer up to the stop r ing and fit two

open end spanners in between the stop ring

retainer and the drive assembly gear.

Using a pin punch and ham mer, lightly tap the

stop ring into the planetary drive shaft groove.

Then pus h down on the two spanners to force

the stop ring retainer over the stop ring.

Figure 6D1-2-50

5. Slide drive assembly up and down planetary

drive shaft ensuring that it moves freely.

Check drive assembly clutch action.

6. Expand fork lever arms and position over drive

assembly pivots.

7. Install planetary drive shaft into the opening of

the drive end housing, aligning the flat on the

ring gear outer sur face toward the opening for

the solenoid switch. Slide the assembly into

position allowing the fork lever pivot to enter

the drive end housing.

Install the sealing rubber behind the pivot,

aligning the 'V' groove with the mating raised

groove on the pivot and thick section toward

the drive end housing solenoid switch

opening.

8. Assemble armature into the field coil housing

with commutator exposed at rear of housing.

Install brush holder over commutator, aligning

the positive brush holders with the brush lead

connections on the field coils.

Position all brushes into their respective

holders, ensuring that the brush leads locate

into the slots on the side of eac h holder. Ins tall

brush springs and carefully bend over the

brush holder spring retaining tags.

9. Ensure that armature to commutator end

cover thrust washer is installed on armature.

Assem ble comm utator end cover, aligning the

field coil braided cable grommet with the

cutout in the commutator end cover.

Install correct adjustment washers and horse

shoe clip.

Assemble dust cover onto commutator end

cover and align sc rew holes in dust cover with

commutator end cover and brush holder.

Install dust cover securing screws and tighten

to the correct torque specification.

DUST COVER

SECURING SCREW

TORQUE SPECIFICATION 1.4 – 2.0 Nm

10. Assemble the field coil housing to the drive

end housing, aligning the cutout in the field

coil housing with the sealing rubber in the

drive end housing. Carefully fit the armature

into the planetary drive. It may be necessary to

rotate the pinion gear slightly to enable the

armature gear to engage the planetary gears

(do not force entry).

11. Install through bolts and tighten to the correct

torque specification.

THROUGH BOLT

TORQUE SPECIFICATION 7.5 Nm

12. Lightly coat solenoid switch plunger with

Molybdenum Disulphide grease.

NOTE: Do not under any circumstances allow

grease on the rear face of the plunger. If too m uch

grease is applied, it may enter the contact c hamber

of the solenoid switch and cause contact problems.

13. Assemble return spring and plunger to

solenoid switch.

Pull pinion gear forward and assemble

solenoid switch assembly to drive end

housing, ensuring that plunger hooks over

drive assembly fork lever.

Ensure that solenoid switch housing is

correctly aligned with drive end housing, that

is with terminal 30 facing away from field coil

housing. Install and tighten solenoid switch to

drive end housing mounting screws to the

correct torque specification.

SOLENDOID SWITCH TO

DRIVE END HOUSING

MOUNTING SCREW

TORQUE SPECIFICATION

5.5 Nm

14. Install field coil braided cable and terminal

over solenoid switch lower threaded terminal.

Install washer and nut to threaded terminal

and tighten to the correct torque specification.

THREADED TERMINAL NUT

TORQUE SPECIFICATION 9 Nm

15. With the starter motor reassembled, a No

Load test should be conducted, refer to

2.1 PERFORMA NCE TESTING in this

Section.

Failure of the starter motor to perform

according to the No Load specif ication m ay be

due to tight or dirty brushes or high res istance

connections. Rectify any faults found.

3. DIAGNOSIS

Many starting problems can be categorised within the following classifications:

1. The starter motor will not crank the engine.

2. The engine will crank at normal speed, but will not start.

3. The starter cranks the engine very slowly.

If the engine is cranked over by the starter motor at the normal speed, but will not start, the problem is in the

ignition system, fuel system or engine, rather than a fault in the starting system.

Before r emoving the s tarter m otor, when investigating a starting pr oblem, f ollow the procedures outlined in the

accompanying diagnostic charts.

SYMPTOM PROBABLE FAULT

A. Speed, torque and current low. A. High resistance in motor. Check field to

terminal connection, condition of brushes and

their connections and check for dirty brushes

or burnt commutator.

B. Speed and torque low, current high. B. Tight or worn bearings, bent armature shaft,

insufficient end play, armature fouling pole

shoe, short-circuited armature, earthed

armature or field coil.

C. Speed and current high, torque low. C. Short circuited windings in field coil.

D. Armature does not rotate. No current. D. Open circuited armature, field coils or

solenoid. If commutator is badly burned,

there may be poor contact between brushes

and commutator, owing to excessively worn

or sticking brushes.

E. Armature does not rotate. High current. E. Earthed field winding or short-circuited

solenoid switch. Armature physically

prevented from rotating.

F. Excessive brush movement causing arcing

at commutator. F. Low brush spring tension, worn or out-of-

round commutator, 'thrown' or high segment

on commutator, or insulation protruding

between segments.

G. Excessive arcing at commutator. G. Defective armature windings, sticking

brushes or dirty commutator.

H. Armature rotates but pinion does not mesh

with ring gear. H. Pinion bearing fouled, burred, damaged

flexplate/ring gear or broken pinion teeth.

VT Series II models are fitted with a timed security override. Turn ignition switch to the ON position and security

override will occur in two hours. (Theft alert indicator LED stops)

If engine now cranks then fault is in the theft deterrent system. Refer to Section 12F THEFT DETERRENT in the

VT Series I Service Information.

If engine still does not crank then continue with this diagnostic procedure.

Techline

NO CRANKING, NO SOUND FROM SOLENOID

STEP ACTION RESULT YES NO

1• Turn headlamps and dome lamps on, turn ignition

to start position. Lamps dim? Go to Step 2. Go to Step 3.

2• Check battery.

• Charge battery.

• Check generator.

• Check cranking voltage at battery posts.

• Check current draw.

Is 9.6 volts

present? Go to Step 7. Test battery.

If OK repair starter.

3• Turn on radio. Operate

OK? Go to Step 4. Go to Step 6.

4• Check voltage at solenoid switch terminal ‘50’. Is 7.0 volts

present? Repair starter. Go to Step 5.

5• With key in start position, check at ignition terminal

‘50’. Is 7.0 volts

present? Repair wiring ignition

switch to starter

motor.

Replace ignition

switch.

6• Check engine main wiring harness fusible link and

ignition connections.

7• Check voltage from engine block to negative post.

Key in start position (positive lead on block). Is 0.5 volt or

present?

Clean and tighten

negative cable

connection, and/or

replace cable.

Go to Step 8.

8• Check cranking voltage at starter ‘B’ terminal. Is 9.0 volts

present? Check fuse and

engine to MWH

connectors.

Clean and tighten

positive cable

connection, and/or

replace cable.

SLOW CRANKING, SOLENOID CLICKS OR CHATTERS

Check : Battery state of charge. Refer to Section 12A BATTERY AND CABLES in the VT Series Service I

Information.

Visual condition of battery cables and connections.

If battery needs charging, carry out generator and battery drain check , charge battery and check cranking again. If

trouble has not been found proceed.

Remove engine fuse link from engine compartment fuse housing. This prevents fuel injection and ignition during

engine cranking. Make all voltmeter readings with ignition key in start position.

STEP ACTION RESULT YES NO

1• Measure cranking voltage at battery terminal posts. Is 9.6 volts

or more

present?

Go to Step 2. Go to Step 3.

2• Measure voltage from battery negative terminal to

engine block (positive lead on block). Is 0.5 volt or

present?

Repair negative

cable and

connections.

Go to Step 4.

3• Charge and load test battery. Is battery

OK? Repair starter. Replace battery.

4• Measure voltage at solenoid switch ‘30’ (B+)

terminal, clean and tighten connections at starter. Is 9.0 volts

or more

present?.

Repair starter. Go to Step 5.

5• Clean and tighten positive cable connections.

• If OK replace cable.

This procedure is designed for use on engines and batteries at room temperature or normal operating

temperatures. It also assumes there are no engine defects which could cause cranking problems. To use it under

other conditions might result in misdiagnosis.

4. SPECIFICATIONS

Type ......................................................................... Bosch DV, four pole, four brush with

planetary drive train

Rotation (drive end view)............................................ Clockwise

Number of pinion teeth............................................... 9

No load test:

Maximum current ....................................................... 125 amps at 11.5 volts

rpm ......................................................................... 5300

Lock test:

Maximum current (including solenoid) ....................... 740 amps

Volts ......................................................................... 4 volts

Torque........................................................................ 20 Nm

Solenoid Test (solenoid detached from starter motor):

Pull in voltage............................................................. 7.8 volts @ 20°C

Hold-in winding resistance ......................................... 1.16 – 1.3 ohms @ 20°C

Pull-in winding resistance........................................... 0.248 – 0.281 ohm @ 20°C

Armature end play...................................................... 0.05 – 0.30 mm

Armature laminations permissible

out-of-round........................................................ 0.5 mm

Commutator:

Maximum permissible out-of-round............................ 0.1 mm

iameter - New............................................................. 32.3 mm

Minimum diameter...................................................... 31.2 mm

Depth of undercut....................................................... 0.8 mm

Brushes:

Minimum length.......................................................... 7 mm

Field coil winding resistance....................................... 1 Mohm or greater

5. TORQUE WRENCH SPECIFI CATIONS

Through bolts........................................................................ 7.5

Pole screws........................................................................... 25

Solenoid attaching bolts........................................................ 5.5

'30' terminal nut..................................................................... 9.8 – 11.3

'50' terminal nut..................................................................... 9.0

'Dust cover securing screws................................................. 1.4 – 2.0

Starter motor to cylinder block mounting bolts...................... 40 – 60