d. Drive Assembly.
(a) See figure 14-15 for adjustments.
(1) Smooth burrs, nicks and rough spots on
splines and pinion teeth using a fine stone or crocus
cloth dipped in cleaning solvent, Federal Specification
(2) Smooth rough spots, scoring, scratches and
nicks on inside bore of sleeve bearings and all sur-
faces of bronze bearings using crocus cloth dipped in
cleaning solvent, Federal Specification P-D-680.
e. Solenoid Assembly Repair.
(1) Check relay windings for shorts or grounds
Replace relay if windings are de-
(2) Replace relay if contact assembly shows de-
fects such as warpage, cracks, or broken springs.
(3) Minor burns or pits on contact surfaces
If conditions are severe, replace
relay. Do not use a file to dress severely burned or
pitted contact surfaces.
f. Field Coil Assembly.
(1) Smooth minor scratches, burrs, and nicks
on machined surfaces of frame using fine mill file,
(2) Repair damaged threads in frame. Repair
damaged threads on field coil terminal stud.
(3) Replace starter assembly if field coil insul-
ation resistance is less than one megohm.
14-30. Reassembly and Adjustments.
Reassemble electric starter in
reverse order of disassembly. See figures 14-11
Perform the following adjust-
ments during reassembly.
(1) Solenoid relay plunger shaft.
(a) See figure 14-14. Connect 12 Vdc
across relay terminals A and B. Using a jumper,
momentarily connect lead terminal C to terminal A to
pull the relay plunger into the sealed position. Place
a straight edge across the relay case as shown.
Measure the distance from the shaft shoulder to the
This dimension should be 7/32 inch
maximum for proper assembly, and the self-locking
nut will be tight after assembly. Disconnect power
from terminals A and B.
(b) If the shoulder to straight edge dimen-
sion exceeds 7/32-inch, the self-locking nut must be
installed and tightened until the end of the nut and the
end of the shaft are flush as illustrated in figure 14-
14. This procedure will provide adequate overtravel.
(b) Remove motor field coil connector
from the motor switch terminal stud.
(c) Remove ground lead assembly connect-
ing motor solenoid relay terminal and starter ground
(d) Remove solenoid relay lead assembly
connecting battery switch terminal stud and battery
solenoid relay terminal.
(e) Connect a 24-volt battery supply to
battery solenoid relay terminal and motor solenoid
(f) Momentarily hold a jumper lead from
the motor switch terminal stud to the motor solenoid
The pinion will now shift into
cranking position and remain so until the battery
(g) Push pinion back toward armature to
take up slack movement.
(h) Check for 0.020- to 0. 050-inch clear-
ance between thrust washer and pinion. To adjust,
remove inspection plug and gasket. Adjust clear-
ance to 0. 020 to 0. 050 inch by turning shaft nut as
shown in figure 14-15.
(i) Connect a test light or other continuity
checker between the battery switch terminal and
motor switch terminal stud.
(j) Connect one of the posts of a 24-volt
battery to the battery solenoid relay terminal.
Connect the other battery post to the motor solenoid
(k) Place a 0. 983-inch spacer block
(figure 14-15) between the pinion and thrust washer
and momentarily hold a jumper lead from the motor
switch terminal stud to the motor solenoid relay
The pinion will now shift against the
spacer block and remain so until the jumper lead is
disconnected. The motor must not run. The motor
must run when the distance between the pinion and
thrust washers is 0. 500 inch.
(1) An open circuit should be indicated be-
tween the battery switch and motor switch terminals.
If continuity exists, decrease the pinion clearance
((a) above) to the minimum limit of 0.020 inch and
recheck to make sure an open circuit now exists.
(m) Disconnect battery and test equipment
and install motor field connector, ground lead and
solenoid relay lead.
(n) Install inspection plug and gasket,
14-31. Test and Installation.
(2) Drive assembly pinion clearance.