1992 MAZDA PROTEGE Workshop Manual

STARTING SYSTEM G
STARTER
Removal / Installation
1. Remove in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary.
3. Install in the reverse order of removal.
37-52 (3.8-5.3, 27-38)
I 9.8-12 N-m (100-120 cm-kg, 87-104 in-lb)
9 I
1 1 ~ /;’ (1.9-2.6, 14-19)
I
9.8-12 N.m /
(100-120 cm-ka. 87-104 In-lb) (3.8-5.3, 27-38)
L-
\\ 37-52 ,d-5.3. 27-38
REMOVE THE STARTER
AS SHOWN IN THE FIGURE
N-m Im-ka. ft.lb 1
I
031JOGX.06
1. Battery 5. Starter
2. intake manifold bracket Disassembly I Assembly.. . . . . . . . . . . . page G-26
3. S terminal wire Inspection.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page G-28
4. B terminal wire 6. Starter bracket
G-25

G
Disassembly / Assembly STARTING SYSTEM
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
2. Inspect all parts and repair or replace as necessary.
3. Assemble in the reverse order of disassembly, referring to
Assembly Note.
BP ATX
1, Magnetic switch 6. Planetary gear
Inspection.. . . . . . . . . . . ..I.........I..I..I... page G-28 7. Front cover
2. Rear cover 8. Lever
3. Brush holder assembly 9. Drive pinion
Inspection.. . . . . . . . . . . . page G-28 10. Internal gear
-_/I
4. Armature 11, Gear shaft
Inspection ..,..,..,..,..,......,..,.., ,...... page G-29 12. Bearing
5. Yoke assembly Inspection .,........,..,..,.................. page G-30
2.4-4.4 N.m (24-45 cm-kg, 21-39 In-lb)
in-lb)
4.1-1.5 N-m (42-77 cm-kg, 36-67 in-lb)
G-26

STARTING SYSTEM G
BP MTX AND B6
3.6-7.1 N.m
(39-72 cm-kg, 34-62 in-lb)
4.1-7.5 N.m
(42-77 cm-kg, 36-67 in-lb)
@
0
2.4-4.4 N.m
(24-45 cm-kg, 21-39 in-lb)
1. Magnetic switch 5. Front cover
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page G-28
6. Lever
2. Rear cover 7. Drive pinion
3. Brush holder assembly 8. Armature
Inspection.. .,..,........................... page G-28 Inspection .,,..,...............,.,........... page G-29
4. Field coil 9. Bearing (if equipped)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page G-29 Inspection.. ,....,......................,... page G-30
--_I__-
03UOGX-06
03UOGX-06
Disassembly Note
Drive pinion
1. Remove the stopper for the overrunning clutch with a pipe
as shown in the figure.
Assembly Note
Drive pinion
1. Set the drive pinion onto the armature (66, BP SOHC) or
gear shaft (BP DOHC), and install the ring.
2. Install the stopper with the
SST and an arbor press as shown
in the figure.
G-27

G STARTING SYSTEM
t
03UOGX.0%
03UOGX.07(
03UOGX.07
03UOGX-072
03UOGX-07:
G-28
BRUSH SPRING
Inspection
Magnetic switch
1. Continuity (S terminal:M terminal)
Check for continuity between S and M terminals with ohm-
meter. Replace the magnetic switch it there is no continuity.
2. Continuity (S terminal-Body)
Check for continuity between the S terminal and the body
with ohmmeter. Replace the magnetic switch if there is no
continuity.
3. Grounding
Check continuity between M and B terminals with an ohm-
meter. Replace the magnetic switch if there is continuity.
.-.’
Brush and .brush holder
1. Insulation
Check continuity between each insulated brush and the
plate with an ohmmeter. Replace the brush holder if there
is continuity.
2. Measure the force of the brush spring with a spring balance.
3. Replace the spring if necessary.

STARTING SYSTEM G
WEAR LIMIT
/ -- _._- .------
03UOGX-07L i
-----.
i
03UOGX 076
03UOGX-07
Brush
If a brush is worn almost to or beyond the wear limit, replace
all of the brushes.
Type
--pFeE?~Ix _~~_ -.~+~~zE~~:
Standard - mm (In) 1
--.-
Minimum mm (In) 11.5 (0.453) 10.0 (0.39)
Field coil
1. Check for continuity between the M terminal wire and brush-
es with an ohmmeter. Replace the yoke assembly if there
is no continuity.
2. Check continuity between the M terminal wire and yoke with
an ohmmeter. Replace the yoke assembly if there is con-
tinuity.
3. Check if the field coil is loose. Replace the yoke assembly
if necessary.
Armature
1. Check continuity between the commutator and the core with
an ohmmeter. Replace the armature it there is continuity.
2. Check continuity between the commutator and the shaft with
an ohmmeter. Replace the armature if there is continuity.
G-29

G STARTING SYSTEM
1 03lJOGX.079
23LJOGX-011
I I OBUOGX-081
3. Place the armature on V-blocks, and measure the runout
with a dial indicator.
If the runout is not within specification, repair it with a lathe
or replace the armature.
Runout: 0.05mm (0.002 in)
Maximum: O.lmm (0.004 in)
4. Replace the armature if the outer diameter of the commu-
tator is almost at or less than the grind limit.
5. If the commutator surface is dirty, wipe it with a cloth; if it
is rough, repair it with a lathe or fine sandpaper.
Engine
Grind limit mm (in) 1 B6 1 BP (MTX) 1 BP (ATX)
31.4 (1.24) 1 28.8 (1.13)
6. Segment groove depth
If the depth of the mold between segments is almost at or
less than the minimum, undercut the grooves to the stan-
dard depth.
Depth: OS-0.8mm (0.02-0.03 in)
Minimum: 0.2mm (0.008 in)
Bearing (if equipped)
1. Check for abnormal noise, looseness, or sticking.
2. Replace the bearing(s) if necessary.
I
03UOGX-082
G-30

STARTING SYSTEM G
STARTER INTERLOCK SWITCH (MTX)
CONTACT
IGNITION SWITCH
IG2 ROD
p IG1 ‘NTERlfM$TCH
i BATTERY
I
STARTER
For operator safety, if the clutch pedal is not depressed during starting, battery power will not be supplied
to the starter and the engine will not crank.
Interlock Switch
Inspection
1. Disconnect the interlock switch connector.
2. Connect an ohmmeter to the switch.
3. Check the continuity.
Clutch pedal
----- I_
Depressed
Released 4.
Replace the switch if necessary.
Continuity
--
Yes
No
G-31

--
-,