1987 MAZDA 626 Workshop Manual

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

OC
Stopper
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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.
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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.
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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.
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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)
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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)
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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).
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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.
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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.
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3. Ground of magnetic switch
Check for continuity between ©and ©terminals
using a circuit tester. Replace the magnetic switch
if there is continuity.
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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.
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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.
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Yoke
Check for damage. Replace if necessary.
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Bearing
Check for abnormal noise, looseness, binding.
Replace the bearing if there is any problem.
Note
Use a bearing puller to remove the bearings.
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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.
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\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)
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Brush holder
Check that the brush slides smoothly inside the
brush holder.
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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.
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STARTER (GASOLINE ENGINE, 1.4 KW TYPE) 5
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Internal gear
Drive pinion Gear shaft
Snap ring
Stopper
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Snap ring
Stopper
Overrunning
\= clutch
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ASSEMBLY
Assemble in the reverse order of disassembly, refer-
ring to the assembly note.
Assembly Note
Lubricate
During assembly lubricate the following points:
1. Gear of armature shaft
2. Internal gear and planetary gears
3. Plunger circumference
4. Lever
5. Ball
6. Gear shaft spline
7. Front bracket housing
Installation of Overrunning Clutch
1. Install the washer, internal gear, drive pinion stop-
per, and the snap ring on the gear shaft.
2. Press the stopper and the snap ring into position
as shown in the figure.
Installation of lever
Check the lever faces in the correct direction.
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5 STARTER (GASOLINE ENGINE, 1.4 KW TYPE)
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86U05X-038
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Installation of Brush Holder
Install the brush holder assembly and rear cover and
align the through bolts.
CHECKING OPERATION
Magnetic Switch
Make the following tests:
Pull-out test
1. Check that the pinion is pulled out when 12V is con-
nected to the S terminal and the body is grounded.
2. Measure the pinion gap while the pinion is pulled
out.
Specification: 0.5—2.0 mm (0.02—0.08 in)
3. Adjust the pinion gap with an adjust washer (drive
housing front cover—magnetic switch) if it is not
within specification.
Return test
1. Disconnect the motor wire from the M terminal, and
then connect the battery power to the M terminal
and ground the body.
2. Pull out the overrunning clutch with a flat-tip screw-
driver. Check that the overrunning clutch returns
to its original position when released.
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