engine MAZDA 626 1987 Workshop Manual

STARTER (GASOLINE ENGINE, 0.85, 0.95 KW TYPE) 5
4BG05X-090
4BG05X-091
4BG05X-092
Drive Pinion and Housing
1. Pinion gear
(1) Check for wear or damage of the pinion gear.
(2) Replace if necessary.
(3) If the pinion gear is seriously damaged, also
check the flywheel ring gear.
2. Bushing
(1) Check for wear or damage.
(2) Replace if necessary.
3. Switch coil
(1) Check for continuity between the M terminal
and the body by using a circuit tester.
(2) Replace the switch if there is no continuity.
PERFORMANCE INSPECTION
Magnetic Switch
Disconnect the terminal M wire, and make the fol-
lowing tests.
Pull-in Test
The switch is normal
if
the pinion ejects outward when
the battery is connected as shown in the figure.
Caution
Do not supply power continuously for more
than 10 seconds.
Hold-in Test
1. After completing the pull-in test, disconnect the wire
from terminal M (with the pinion left ejected).
2. The hold-in coil is functioning properly if the pin-
ion does not return.
4BG05X-093
5-43

5 STARTER (GASOLINE ENGINE, 0.85, 0.95 KW TYPE)
(TM (TM /AgLjM) terminal
xtsfif
4BG05X-094
Return Test
1. Connect the battery between terminal M of the
magnetic switch and the body, as shown in the
figure.
2. Pull the pinion out manually to the pinion stopper
position.
3. The pinion should immediately return to its origi-
nal position when it is released.
No-load Test
1. After adjusting the pinion gap, form a test circuit
with a voltmeter and an ammeter.
Note
Use wires as thick as possible and tighten
each terminal fully.
2. Close switch "K" to run the starter.
3. If the voltmeter and ammeter show the following
values while the starter is running, it is normal.
0.85 kW
type
0.95 kW
type
Battery voltage (volt) 11.5
Current
(ampere) 60 or less
Gear shaft speed (rpm) 6,500 or more
6,600
or more
4. If any abnormality is noted, check it according to
"INSPECTION"
5—44

STARTER (GASOLINE ENGINE, 1.4 KW TYPE) 5
STARTER (GASOLINE
ENGINE, 1.4
KW TYPE)
STARTING SYSTEM
76G05X-041
ON-VEHICLE INSPECTION
Charge the battery fully before starting the following
inspection.
1. Turn the ignition switch to the start positron.
2. Check that the starter motor operates.
3. If the starter does not operate, check the voltage
between S terminal and ground using a voltmeter.
4. If the voltage is 8V or more, the starter is mal-
function.
5. If less than 8V, the wiring harness is malfunction.
Caution
If the magnetic switch is hot, it may not func-
tion even though the voltage is standard volt-
age or more.
Note
The cranking speed is greatly affected by the
viscosity of the engine oil.
86U05X-031
5-45

5 STARTER (GASOLINE ENGINE, 1.4 KW TYPE)
REMOVAL
1. Disconnect the negative battery cable.
2. Disconnect the wiring from the starter.
3. Raise the front of the vehicle and support it with
safety stands.
4. Remove the starter bolts.
5. Draw out the starter from lower side of the vehicle.
Note
Remove the lowest starter bolt last.
76G05X-042
DISASSEMBLY
86U05X-083
1. Magnetic switch
2. Plunger and spring
3. Rear housing
4. Brush holder assembly
5. Armature
6. Ball
7. Planetary gear
8. Drive housing front cover
9. Lever
10. Drive pinion
11. Overrunning clutch
12. Internal gear
13. Yoke assembly
14. Gear shaft
Caution
Do not strike the yoke with a hammer, drop it or put it in a vise when disassembling the
starter.
5—46

STARTER (GASOLINE ENGINE, 1.4 KW TYPE) 5
Magnetic Switch
Remove the following parts:
(1) M terminal nut
(2) Wire
(3) Switch installation screws
(4) Magnetic switch
(5) Plunger and plunger spring
86U05X-33
Rear Bracket and Brush Holder
Remove the following parts:
(1) Brush holder installation screws
(2) Through bolts
(3) Rear cover
(4) Wave washer
(5) Brush holder assembly
Note
Put an aligning mark on the yoke and rear
bracket for reassembly before removing the
rear bracket.
7BU05X-034
Yoke and Armature
Remove the armature and yoke.
Note
Put an aligning mark on the yoke and front
bracket for reassembly before removing the
front bracket.
7BU05X-035
Overrunning Clutch, Planetary Gears, and Inter-
nal Gear.
Remove the following parts:
(1) Gasket
(2) Plate
(3) Planetary gears
(4) Internal gear
(5) Drive pinion
Note
Do not lose the ball.
7BU05X-110
5—47

5 STARTER (GASOLINE ENGINE, 1.4 KW TYPE)
86U05X-034
Snap ring
Internal gear
Drive pinion I Gear shaft
r i
rt
n I I Washer

OC
Stopper
7BU05X-037
Overrunning Clutch Stopper
1. Remove the overrunning clutch stopper using a
pipe.
2. Disassemble the drive pinion, internal gear and
washer from the gear shaft.
Brush and Brush Holder
Remove the brush from the brush holder using a flat-
tip screwdriver.
7BU05X-038
5-48

STARTER (GASOLINE ENGINE, 1.4 KW TYPE) 5
INSPECTION
Armature
1. Ground of armature coil
Check for continuity between the commutator and
the core using a circuit tester. Replace the arma-
ture if there is continuity.
67U05X-048
2. Insulation of armature coil
Check for continuity between the commutator and
the shaft using a circuit tester. Replace the arma-
ture if there is continuity.
67U05X-049
Runout of commutator
(1) Place the armature on V blocks, and measure
the runout using a dial gauge.
(2)
If
the runout is excessive, replace the armature.
Runout: 0.05 mm (0.002 in)
Maximum: 0.1 mm (0.004 in)
7BU05X-039
Outer diameter of commutator
Replace the armature if the outer diameter of the
commutator is less than the grind limit.
Roughness of commutator surface
Repair using a lathe or fine sandpaper if it is rough;
wipe it with a rag if it is dirty.
Grind limit: 28.8 mm (1.13 in)
7BU05X-040
5-49

5 STARTER (GASOLINE ENGINE, 1.4 KW TYPE)
Segments groove depth
If the depth of the groove is less than standard,
undercut the grooves to the standard depth.
Standard depth: 0.5—0.8 mm (0.02—0.03 in)
Minimum depth: 0.2 mm (0.008 in).
7BU05X-041
Magnetic Switch
1. Wiring damage (©terminal — ©terminal).
Check for continuity between the ©terminal and
the ©terminal using a circuit tester. Replace the
magnetic switch if there is no continuity.
67U05X-053
Wiring damage (©terminal — body)
Check for continuity between © terminal and
body using a circuit tester.
Replace the magnetic switch if there is no con-
tinuity.
67U05X-054
3. Ground of magnetic switch
Check for continuity between ©and ©terminals
using a circuit tester. Replace the magnetic switch
if there is continuity.
67U05X-055
5—50

STARTER (GASOLINE ENGINE, 1.4 KW TYPE) 5
Overrunning Clutch
Turn the pinion shaft by hand and hold the overrun-
ning clutch.
Replace the overrunning clutch if the pinion turns in
both directions or in neither direction.
Note
Do not wash the overrunning clutch with sol-
vent; it is packed with grease and sealed.
86U05X-035
Internal Gear and Planetary Gears
1. Internal gear
Check for wear or damage. Replace if necessary.
2. Planetary gears
Check for wear or damage. Replace if necessary.
67U05X-057
Yoke
Check for damage. Replace if necessary.
67U05X-058
Bearing
Check for abnormal noise, looseness, binding.
Replace the bearing if there is any problem.
Note
Use a bearing puller to remove the bearings.
67U05X-059
5-51

5 STARTER (GASOLINE ENGINE, 1.4 KW TYPE)
Brush and Brush Holder
1. Insulation of brush holder
Check for continuity between the insulated brush
and the plate using a circuit tester. Replace the
brush holder if there is continuity.
67U05X-060
\E
Wear limit line
—r
10.0 mm
(0.39 in)
L 17.5 mm (0.69 in)
2. Brush
Replace the brushes if they are worn beyond the
wear limit, or if the wear is near the limit.
Wear limit: 10.0 mm (0.394 in)
New brush: 17.5 mm (0.689 in)
7BU05X-043
Brush holder
Check that the brush slides smoothly inside the
brush holder.
67U05X-062
4. Brush spring
(1) Measure the force of the brush spring using
a spring balance.
(2) Replace the brush spring if the force is below
specification.
Specification: 7 N (0.7 kg, 1.5 lb)
Note
a) The force is measured at the moment the
brush spring separates from the brush.
b)The force must be 18—24 N (1.8—2.4 kg,
4.0—5.3 lb) for a new brush spring.
86U05X-036
5-52