SUBARU LEGACY 1997 Service Repair Manual

2. Generator
B6M0414A

1Pulley nut


2Pulley


3Front cover ASSY


4Ball bearing


5Bearing retainer


6Screw


7Rotor


8Stator coil


9IC regulator ASSY


10Condenser


11Diode ASSY


12Bolt

13Bolt


14Brush holder ASSY


15Rear cover


16BAT. terminal


17Nut


18Bolt


19Through bolt
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 3.1 — 4.4 (0.32 — 0.45, 2.3 — 3.3)
T2: 63.7 — 83.4 (6.5 — 8.5, 47.0 — 61.5)
6
6-1COMPONENT PARTS
2. Generator

G6M0095
1. Starter
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
G2M0309
2) Disconnect connector and terminal from starter.
3) Remove starter from transmission.
4) Installation is in the reverse order of removal.
Tightening torque:
50±4 N⋅m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
B: TEST
1. MAGNETIC SWITCH
CAUTION:
The following magnetic switch tests should be per-
formed with specified voltage applied.
Each test should be conducted within 3 to 5 sec-
onds. Power to be furnished should be one-half the
rated voltage.
B6M0415A
1) Pull-in test
Connect two battery negative leads onto magnetic switch
body and terminal C respectively. Then connect battery
positive lead onto terminal 50. Pinion should extend when
lead connections are made.
B6M0416A
2) Holding-in test
Disconnect lead from terminal C with pinion extended. Pin-
ion should be held in the extended position.
7
6-1SERVICE PROCEDURE
1. Starter

B6M0417A
3) Return test
Connect two battery negative leads onto terminal 50 and
onto switch body respectively. Then connect battery posi-
tive lead onto terminal C. Next, disconnect lead from ter-
minal 50. Pinion should return immediately.
2. PERFORMANCE TEST
The starter is required to produce a large torque and high
rotating speed, but these starter characteristics vary with
the capacity of the battery. It is therefore important to use
a battery with the specified capacity whenever testing the
starter.
The starter should be checked for the following three items:
1. No-load test
Measure the maximum rotating speed and current under a
no-load state.
2. Load test
Measure the magnitude of current needed to generate the
specified torque and rotating speed.
3. Stall test
Measure the torque and current when the armature is
locked.
B6M0418A
1) No-load test
Run single starter under no-load state, and measure its
rotating speed, voltage, and current, using the specified
battery. Measured values must meet the following stan-
dards:
No-load test (Standard):
Voltage/Current
11 V/90 A, or more
Rotating speed
TN128000-8311: 3,000 rpm, or more
TN128000-8321: 3,350 rpm, or more
8
6-1SERVICE PROCEDURE
1. Starter

B6M0419A
2) Load test (For reference)
Perform this test to check maximum output of starter. Use
test bench which is able to apply load (brake) to starter.
Measure torque value and rotating speed under the speci-
fied voltage and current conditions while controlling brak-
ing force applied to starter.
CAUTION:
Change engagement position of overrunning clutch
and make sure it is not slipping.
Load test (Standard):
TN128000-8311
Voltage/Load
8 V/9.8 N⋅m (1.0 kg-m, 7.2 ft-lb)
Current/Speed
280 A max./900 rpm min.
TN128000-8321
Voltage/Load
8 V/13.7 N⋅m (1.4 kg-m, 10.1 ft-lb)
Current/Speed
370 A, or less/880 rpm, or more
B6M0420A
3) Stall test
Using the same test equipment used for load test, apply
brake to lock starter armature. Then measure voltage,
current, and torque values.
Measured values must meet the following standard.
Stall test (Standard):
TN128000-8311
Voltage/Current
5 V/800 A, or less
Torque
27.5 N⋅m (2.8 kg-m, 20.3 ft-lb) min.
TN128000-8321
Voltage/Current
5 V/1,050 A, or less
Torque
27.5 N⋅m (2.8 kg-m, 20.3 ft-lb) min.
NOTE:
Low rotating speed or excessive current during no-load test
may be attributable to high rotating resistance of starter
due to improper assembling.
Small current and no torque during stall test may be attrib-
utable to excessive contact resistance between brush and
commutator; whereas, normal current and insufficient
torque may be attributable to shorted commutator or poor
insulation.
Starter can be considered normal if it passes no-load and
stall tests; therefore, load test may be omitted.
9
6-1SERVICE PROCEDURE
1. Starter

B6M0421A
C: DISASSEMBLY
1) Disconnect lead wire from magnetic switch.
B6M0422A
2) Remove through-bolts from end frame.
B6M0423A
3) Remove yoke from magnetic switch.
B6M0424A
4) Remove screws securing end frame to brush holder.
B6M0425A
5) Separate yoke from end frame.
10
6-1SERVICE PROCEDURE
1. Starter

B6M0426A
6) Remove brush by lifting up positive (+) side brush
spring using long-nose pliers.
CAUTION:
Be careful not to damage brush and commutator.
B6M0427A
7) Remove armature from yoke.
CAUTION:
Be careful not to drop armature.
B6M0428A
8) Remove screws securing magnetic switch to housing.
B6M0429A
9) Remove housing from magnetic switch.
B6M0430A
10) Remove clutch from housing.
11
6-1SERVICE PROCEDURE
1. Starter

B6M0431A
11) Take out steel ball from clutch.
CAUTION:
Be careful not to lose steel ball.
B6M0432A
12) Remove idle gear from housing.
B6M0433A
13) Remove retainer and roller from housing.
CAUTION:
Be careful not to drop retainer and roller.
B6M0434A
14) Remove coil spring from magnetic switch.
D: INSPECTION
1. ARMATURE
1) Check commutator for any sign of burns of rough sur-
faces or stepped wear. If wear is of a minor nature, correct
it by using sand paper.
12
6-1SERVICE PROCEDURE
1. Starter

G6M0038
2) Run-out test
Check the commutator run-out and replace if it exceeds the
limit.
Commutator run-out:
Standard
0.02 mm (0.0008 in), or less
Service limit
Less than 0.05 mm (0.0020 in)
G6M0039
3) Depth of segment mold
Check the depth of segment mold.
Depth of segment mold:
0.6 mm (0.024 in)
Limit
0.2 mm (0.008 in)
G6M0040
4) Armature short-circuit test
Check armature for short-circuit by placing it on growler
tester. Hold a hacksaw blade against armature core while
slowly rotating armature. A short-circuited armature will
cause the blade to vibrate and to be attracted to core. If the
hacksaw blade is attracted or vibrates, the armature, which
is short-circuited, must be replaced or repaired.
G6M0041
5) Armature ground test
Using circuit tester, touch one probe to the commutator
segment and the other to shaft. There should be no conti-
nuity. If there is a continuity, armature is grounded.
Replace armature if it is grounded.
B6M0435
2. YOKE
Make sure pole is set in position.
13
6-1SERVICE PROCEDURE
1. Starter

B6M0436
3. OVERRUNNING CLUTCH
Inspect teeth of pinion for wear and damage. Replace if it
is damaged. Rotate pinion in direction of rotation (clock-
wise). It should rotate smoothly. But in opposite direction,
it should be locked.
CAUTION:
Do not clean overrunning clutch with oil to prevent
grease from flowing out.
B6M0437
4. BRUSH AND BRUSH HOLDER
1) Brush length
Measure the brush length and replace if it exceeds the
service limit.
Replace if abnormal wear or cracks are noticed.
Brush length:
Standard 15 mm (0.59 in)
Service limit 10 mm (0.39 in)
2) Brush movement
Be sure brush moves smoothly inside brush holder.
B6M0438
3) Insulation resistance of brush holder
Be sure there is no continuity between brush holder and its
plate.
4) Brush spring force
Measure brush spring force with a spring scale. If it is less
than the service limit, replace brush spring.
Brush spring force:
Standard
18.6 N (1.9 kg, 4.2 lb) (when new)
Service limit
6.9 N (0.7 kg, 1.5 lb)
14
6-1SERVICE PROCEDURE
1. Starter

B6M0439A
5. BEARING
1) Rotate bearing by hand; no binding should exist.
2) Rotate bearing rapidly; no abnormal noise should be
heard.
E: ASSEMBLY
Assembly is in the reverse order of disassembly proce-
dures. Observe the following:
1) Before assembling, lubricate disassembled parts at the
points shown in“COMPONENT PARTS 6-1 [C101] and 6-1
[C102]”.
Grease:
ESSO BEACON 325
SCHELL ALVANIA GREASE RA or equivalent
B6M0470A
2) Assembling magnetic switch, clutch, and housing
To assemble, first install clutch to magnetic switch, then
install idle gear, and finally install clutch.
CAUTION:
Do not forget to install steel ball and coil spring to
clutch.
Attach bearing to idle gear beforehand.
B6M0427A
3) Installing armature to yoke
CAUTION:
Do not forget to put felt washer on armature shaft bear-
ing.
B6M0471A
4) Installing brushes
Assemble brush holder to yoke as shown, then assemble
two yoke-side brushes to brush holder.
15
6-1SERVICE PROCEDURE
1. Starter