lock DATSUN 510 1968 Service Service Manual

96

CHAFTER
NINE

@

EK
lle

Correct

Incorrect

ground
As
shown
m

Figure
i
7

place
one
test

probe
onto
the
armature
shaft
and
the
other

probe
onto
each
commutator
bar

ContInuity

IndICates
a

groundt
and
the
armature
must
be

replaced

@

6
Check
the

armature
for
shorts

by
placmg
It

on
a

holdmg
fixture

holdmg
a
hack
saw
blade

over
the
core
and

rotatIng
the
armature
If
the

saw
blade
VIbrates
the
armature

Is
shorted
and

must
be

replaced

7
Check
for

contInuity
by
placmg
the

probes

of
a
tester
on
two
sIde

by
slde

segments
of
the

armature
No

current

passage
mdlcates

an

open

CIrcUIt
The

armature
must
be

replaced
If
read

mgs
are

InCOnslste
t

replace
the
armature

OVERRUNNING
CLUTCH
ASSEMBLY

1

Inspect
the

plmon
assembly
and

screw
leeve

The

screw
sleeve

must
slIde

freely
along
the

armature
shaft
If

damage
IS
detected
or
1f
It
does

not
move

freely
replace
It

Inspect
the

pmion

teeth
for

damage
and
wear

Replace
1f

required

2

Inspect
the
teeth

on
the

flywheel

nng
gear
for

mlssmg
or

damaged
teeth

If
defective
the

fly

wheel

must
be

replaced
BRUSH
HOLDER

1

Usmg
a
CirCUIt
tester

as
shown

In

Figure
18

place
one
test

probe
on
the

rear
cover
and
the

other

on
the

posltlve
SIde

of
the

brush
holder
If

the
tester
shows
conduction
the
brush
holder
IS

shorted
to

ground
or
the
msulator
IS
defective

Replace
the
brush
holder

@

STARTER

MOTOR
BEARINGS

1

Inspect
the

bearmgs
at
eIther
end
of
the
rear

cover
and
the

gear
case

assembly
If

they
show

SignS
of

sconng
or
other

damage
replace
them

Check
the

clearance
of
the
armature
shaft

to
the

bearmgs
It
should
be
less
than
0
0079

In

0
2mm

2
If
the

bearings
are

replaced
new

bearing

clearance
should
be
00012
to
00039

In
0
03

to
0
10mm

MAGNETIC
SWITCH
ASSEMBLY

1

Inspect
the

magnetic
sWItch
contacts
for
de

fects

and

damage
replace
1f

necessary

ASSEMBLY

To
reassemble
the
starter
motor

reverse
the

procedures
used

dUring
disassembly
When

as

sembly
has
been

completed
perform
the

follow

mg
tests

Testing

The
starter

motor
should
be

subjected
to
a

no
load
test
and
a
lock

torque
test

follOWIng

overhaul
to
ensure
that
Its

performance
will
be

satIsfactory
when
mstalled

on
the

engme
These

tests

are
also

helpful
In

detennmIng
the
cause

of

problems
before

dIsassembly

ENGINE
ELECI
RlCAL
SYSTEM
97

No
Load
Lock

Torque
Test

1
Connect
the
starter
motor
in
series
with

a

12
volt

battery
and
antmeter
as
shown
in

Figure

19
The
antmeter
should
be

capable
of

mdIcatIng

1
000

amps

@
Switch

Voltmeter
Ammeter

2
Use

torque
testlng
equipment
to
determine

the

torque
the
motor

develops

3
Connect
a
voltmeter
and
a
vanable
resistor

WhICh
IS
used
to

regulate
the

voltage
Into
the

circwt

4
Close
the
sWitch

and

regulate
the

voltage
as

reqUIred
Figure
20

proVIdes

power
voltage

amperage
and

torque
mformatIon

that
1f
fol

lowed
will
mdIcate
the
condItion
of
the
starter

motor

Power
kw

Voltage
v

@

Test

Diagnosis

1
Low

speed
with

high
current
draw

might
re

sult
from

tIght
dirty
or
worn

bearings
bent

armatlIre
shaft
loose
field
call
or
a
shorted

armatlIre

2
Fatlure
to

operate
With

htgh
current
draw

may
result
from
a

gromlded
or

open
field
coil
a
defectIve
armature
coll
or
a
burned

out
com

mutator
bar

3
Low

torque
low
current
draw
and

low

speed

would
be
caused

by
hIgh
Internal
reSIStance
due

to
loose
connectIons

dirty
commutator
defec

tIve
leads
and

a
burned
out
commutator
bar

4

HIgh
speed
With
low

torque
would
be
caused

by
a

grounded
field
coll

Magnetic
Switch

Assembly
Test

H
the
above
tests
are

satIsfactory
check
the

magnetIc
SWitch

assembly
as
follows

1
Connect

Jumper
cables
between
the

negative

battery
tennmal
and
the
starter
motor
M
term

inal

as
shown
In

Figure
21
Also
connect
the

positIve
battery
terminal
to
the
S
terminal
and

place
a
SWitch
m
senes
in
the
CIrCuit

@
Ignition
switch

9

I

i
j

Battery
Starter
motor

rr

2
Close
the
SWitch
and
measure
the

dimension

given
m

Figure
22
The
dimensIon
should
be
as

specIfied

o
0591m

15mm

100

CHAPTER
NINE

@

1
1

43

44

45

46

49

I

tYV
48

47

37
Alternator
bracket

38
Hex
bolt

39
Hex
bolt

40
lock

spnng
washer

41

8racket
shim

42

AdJusltng
bar

43
Hex
bolt

4
Remove
the

pulley
nut
pulley
rim

fan
and

spacer
from
the

hOUSIng
See

Figure
29

@

000

5
Remove
the
rotor
from
the
drive
end

housmg

by

tappIng
lIghtly
With
a
wooden
hammer

Refer

to

Figure
30

@
1

46
45
43
44

38
39

6
Remove
the

beanng
retainer

by
unscrewing

three
set
screws
and

push
out
the

bearmg
with
an

arbor

press
See

Figure
31

@
A
t

J
r

j

f
1

p
O

7
Pull

the
rear

bearmg
from
the
rotor

assembly

by

usmg
an
arbor

press
or

bearing
puller
as

shown
m

Figure
32

@

104

CHAPTER

NINE

2
When

one
sIde
shows
low
resIstance

and
the

other
shows

high
resIstance
the

dIode
IS
satls

factory
If
both
sIdes
are
low

there
IS
a
short

CIrCUIt
If
both
sIdes
are

hIgh
there

IS
an

open

CIrcUIt
All
diodes
With

open
or
short
ClrC
ts

must
be

replaced

BRUSH

INSPECTION

1

VIsually
check
the
brushes

for

SIgnS
of
wear

or

damage
If

wear
IS

greater
than
the
wear
lIrmt

shown
in

Figure
47

replace
the
brush

2

ChecJ
the
movement
of
the

brush
for
smooth

ness
If

unsmooth
check

and
clean
the
brush

holder

3
To

check

spnng

pressure
place
a
SUItable

block

on
a

platform
scale
and

press
down

the

brush
holder

WIth
the
brush
and

spnng
on
the

block

untIl
the
brush
smks

In
the

holder
to

00394

m

lmm

heIght
from

the
holder
Sub

tract
the

block

weight
from

the

reading
to
derive

the

spnng
pressure
It
should

be
0
77
Ibs
035

kg
If
the

readmg
IS
under
0
44
Ibs
0
2

kg

replace
the

spring
Figure
48
shows
thIS

test

being

performed

ALTERNATOR
OUTPUT

INSPECTION

To
check
alternator

output
remove
the
alter

nator
from
the
vehIcle

and
connect

wumg
as

shown
m

Figure
49

Dq
ve
the
alternator
WIth

a

motor

Through
the
CIrcUItS
shown

m
the
Illustra

tIon

current
flows
from
the

battery
to
the
field

coll
of
the
alternator
RaISe
the

speed
of

the

alternator

slowly
to
the

pOInt
where
no
reverse

flow

eXISts
ThIs

pOInt
should
be
about

2

amps

I
at
1
000

rpm
Increase
the
load

reSIStance
untIl

the
load
current

IS
almost

stopped
and

tlI
rn
off

the
SWItch
RaIse
the
load

current

slowly
and

mcrease
the

speed
of
the

alternator
Observe

that
the

output
current
mcreases
as
the

speed

of
the
alternator

mcreases
If
the

output
is
wlthm

the
above

specmcatIon
at
the

proper

rp
ll
the

alternator

IS

satIsfactory

ALTERNATOR
ASSEMBLY

To
assemble
the
alternator

reverse
the

pro

cedures

given
for

dIsassembly
The
use
of
an

arbor

press
to

mstall
dIodes
and

bearmgs
is

essentIal

so
that

parts
are
not

damaged

VOLTAGE
REGULATOR

The

voltage
regulator
is

mounted
to
the

right

hand

engme
compartment
SIde

wall
and
has
a

removable
cover

Figure
SO
shows
the

regulator

With
the

cover
removed

AdjustIng
the

voltage

regulatpr

reqUIres
special
eqUIpment
not

or

dmanly
avallable
to
the

home
mechanlc
If

trouble
seems
to
be
in
the

regulator
refer
servIce

to
a
Datsun
dealer

or

competent
garage

1
Hose
clemp

3
Hose
clamp

4
Connector
pipe

5
Hose
connector

6
Control
valve

7
Air
pump
with
pulley

9
Air
pump
pulley

11
Bolt

13
Spnng
washer

14
Check
valve

15
Antl
beckllre
elve

17
Connector
tube

19
Hose
c1emp

20
Air
gellery
pipe

22
Air
pum
p
bracket

24
Hex
bolt

26
Spring
washer

27
Adjusting
bar

28
Hex
bolt

29
Spnng
lock
washer

30
Hex
bolt

31
Air
pump
bolt

39
Air
c1eener
to
air
pump

hose

40
Air
pump
to
control

alve
hose

41
Air
pump
to
anti

beckllre
velve
hose

43
Antl
backllre
valve
to

connector
hose

45
Hose
clemp

46
Hose
clemp

48
Hose
c1emp

49
Air
pump
belt

50
Rocker
cover
to
alf

clBllner
hosa

51
Hose
band

54
Velve
1I0w
guide

55
Flow
gulda
valve

brackBt

56
Eveporatlve
control

tube
57
Evaporative
control

tube

58
Eveporatlve
control

tube

59
Hose
clamp
60
Screw

61
Spring
washer

62
Screw

63
Spring
washer

64
Main
breather
tube

50
15
i

2
@

24

11
3

10
9
r

7
8

JI
4
J

c
U
12
24
22
19
18
@

20
ta

21
1
frontBxhaust
tube

2
Exheust
gasket

3
Plein
wesher

4
Spnng
wesher

5
fixing
nut

6
Center
exhaust
tube

7
Exhaust
tube
U
bolt
clamp

8
Exhaust
tube
U
bolt
clamp

9
Spring
wesher

10
Hex
nut

11
Reer
exheusttube

12
Exhaust
rubber

13
Plain
washer

14
Lock
washer

15
Spnng
washer

16
Hex
bolt

17
Muffler
essembly

18
Exhaust
tube
U
bolt
clamp

19
Exhaust
tube
U
bolt
clamp

20
spring
wesher

21
Hex
nut

22
Rear
mount
bracket

23
Rear
mount
brecket

24
Rubber
henger
i

22
rnL
T
II

19

2
16

rr

I
II
l
r
@

1
Front
exhaust
tube

2
Exhaust
tube
clamp
assembly

3
Exhaust
tube
clemp
assembly

4
Muffler
clamp

5
1
Front
lower
hook

5
2
Front
lower
hook

5
3
Hex
bolt

5
4
Hex
nut

5
5
Lockwasher

5
6
Extenor
mounting
rubber

Insulator

5
7
Extenor
mounting
rubber

Insulator

5
8
Extenor
mounting
shim

5
9
Extenor
mounting
shim

10
U
bolt

11
Clamp
plate

12
Hex
bolt

13
Hex
nut

14
Plain
washer

15
lockwasher

16
Rubber
hanger

17
Hanger
strap

18
lock
plate

19
Hex
bolt

20
Hex
nut

21
lockwasher

22
Exhaust
gasket

23
Hex
nut

24
Plain
washer

25
lockwasher

26
Muffler
kit
l
o

o
t
I
N
III

128

CHAPTER
ELEVEN

1
Clutch
disc

assembly

2
Clutch
cover

3
Hex
bolt

4
Lock
washer

5
Withdrawal
lever

6
Withdrawal
lever

ball

pin

7
Lock
washer

8
Retainer

spnng

9
Clutch
sleeve

10
Release

bearing

11
Holder

spring

12
Dust
cover

13
Return

spring

14
Push
nut

15
Hex
nut
CD

9

11

8

6

7

1
Release

beanng
2

Beanng
sleeve
2

5
13

12

15

14

Clutch

Inspection
and

Repair

1

Thoroughly
clean
all
dISassembled

parts
ex

cept
for
the

dISc

assembly
and
release

bearmg

In
a
SUItable
solvent

2
Check

all

parts
carefully
for
wear
cracks

and
other
defects

3
Check
the
clutch
disc
for
oil
soaked

or

cracked

faCIngs

warpmg
loose
nvets

exceSSIve

wear
and
broken

spnngs

4
Check
the

pressure
plate
for

sconng
bum

marks
blue
tlnted
areas
and
cracks

If

any
of

the
above
condItIons
are
found

re

place
the
clutch
dISC
and
or
the

pressure
plate

Replace
dISC

assembly
1f

facmg
IS
worn
so
that

the

facmg
heIght
above
the

nvet
IS
less
than

00118m
03mm

Very
mmor
bum

marks
and

CLUTCH
TRANSMISSION
AND
DRlVESIIAFI
133

C
8

Q@J

@

C

Operating
Cylinder
Reassembly

1
Soak

pISton
cup
m
brake
flUid
and
Install
It

In
the
same

pOSitIOn
as
before
removal

2

Apply
brake
flUid

to
the

cylInder
and

pIston

before

mstalImg
piston

3

Replace
all

parts
m
the
reverse
order
of

removal

Operating
Cylinder
Installation

1
RemstallatIon
IS
the
reverse
of
removal

2
Bleed
aIr
from
the

hydraulIc
system

3

Adjust
the

pushrod
so
that
withdrawal
lever

end

play
IS
0
0787
to
0
1181
In
2

0
to
3
Omm

Procedures
for

the

adjustment
are

given
below

WITHDRAWAL
LEVER
AD
JUSTMENT

Correct

adjustment
of
the
clutch
withdrawal

lever
IS
essentIal
InsufficIent
free
travel
between

the
release

bearmg
and

dIaphragm
fingers
can

cause
the
clutch
to

slIp
ExceSSIve
free
travel
can

prevent
full

dISengagement
of
the
clutch
Refer

to

Figure
11

1
Loosen
lock
nut

2
SCrew
In
the

pushrod
fully
with
the

adjustmg

nut

3
Unscrew

adJustmg
nut
1
turns

TIghten

lock
nut

J

4
Check
the
end

play
of
the
wIthdrawal
lever

End

play
should
be
0
0787
to
0
0906
in
2
0
to

2
3mm
The
correct
end

play
will

give
a
clear

ance
of
0
0512
m

1
3mm
between
the
release

bearmg
and

diaphragm
fingers
@

1
Lock
nut

2

AdJustmg
nut

3
Wrthdrawal
ever

4
Release
beer

ng

5

Diaphragm
spnng
20
to
30

0
079
to
0
11

B

Unit
mm
m

5
If
the
above

adjustment
does
not
result
in

satIsfactory
clutch

operatIon
the
clutch
dISC
is

probably
worn

excessIvely
and
will

reqUire
re

placement
as

preVIously
dIScussed

BLEEDING
CLUTCH
SYSTEM

AIr
In
the
clutch

hydraulIc
system
makes
shIft

Ing
gears
extremely
difficult
1f
not

impOSSIble

To
bleed
the

system
proceed
as
follows

1
Remove
the
bleed
screw
dust

cap
from
the

operating
cylInder

2
Attach
a
bleeder
hose
to
the

bleed
screw

Immerse
the
other
end
of
the
hose
m
a
container

f

hydraulIc
brake
fluid

3
Check
to
see
that
clutch
master

cylInder

reservoir
IS
full
of
brake
flUid

ReplenISh
if

necessary

4

Open
the
bleeder
screw

three
quarters
of
a

tlIrn
and
have
an
assistant

pump
the
clutch

pedal
slowly
Pump
the
clutch
until
the

flUid

entenng
the

contatner
is
clean
and
free
from

bubbles

5

TIghten
bleed
screw

Replace
dust

cap
Refill

the
flUid

reservoir

M

I

CL
SMISSION
AND
DRIVESIIAF1
137

i@

v

l
ll
r

1
Neutral

gear
swrtch

2
TransmISSIon
swllch

thud

geu

3

Reverse
gear
SWitch

@1
Control
arm
14
Return
spnng

2
StnkBr

bushmg
15
Re
erse
check
ball

3
O

nng

cep
16
Check

spnng

4
O

nng
17
Retalmng
pm

5
Control
O

nng
18
Slnlung
rod

6

First
and
second
fork
rod
19
Slnlung
pm

7
First
and
second
shill
fork
20
O

nng

8
Thud

and
fourth
lork
rod
22
Control
arm

pm

9
Third

and
fourth
shill
fork
23
Control
washer

10
Reverse
fork
rod
24
Control
arm

bushmg

11
Reverse
shill
fork
25
Control

spnng

12
Rolled

pm
26
Thrust
wesher

13
Reverse
fork

pm
27
Retammg

pm

9

0

11

f
Ir

foUr

1
i

1
k

jl

n

1

1
l

28
Control
lever
35
Lower
washer

29
Control
lever
knob
36
Self

lockmg
nut

31
Washer
37
Rubber
boot

32
Controlle
er
rubber
41
Tnmsmlsslon
hole

cover

33
Washer
42
Tappmg
screw

34

Upper
washer

29

c

28

37

16
t

f

f

1

I
13

1

12
5

T

2V

T
19

25
26

20
31

e
32

@
35

@
36