Pioneer 1200 Maintenance Service Manual page 172

12
ELECTRICAL COMPONENTS: FE400 ENGINE
Starter/Generator Assembly
1. Connect the brush wires to the holders using four lock washers (26) and four screws (25). Make sure the
crossover leads are also connected. Tighten the screws to 31 in-lb (3.5 N·m) (Figure 12-4, Page 12-3).
2. Install the commutator. Lift the brush springs out of the notches in the brushes and pull the brushes back
from the center of the commutator end cover to avoid interfearance. The springs will rest on the sides of
the brushes and help prevent them from sliding to the center (Figure 12-7, Page 12-4).
3. Install the commutator end cover (23) onto the armature shaft. Align the locating pin and hole in the cover.
Install two M6 x 180 mm bolts (20) and tighten to 100 in-lb (11.3 N·m) (Figure 12-3, Page 12-3).
4. Push the brushes down into the holders. Place springs into the notches in the brushes. Install the brush
cover (30) that has the drain hole in it next to the A2 terminal. Install the remaining three brush covers
(29) onto the openings in the commutator end cover (23) (Figure 12-4, Page 12-3).
Disassembly of the Starter/Generator to Service the Armature/Commutator
1. Remove the two bolts (20), and pull commutator end cover (23) free of the starter/generator housing (24)
(Figure 12-3, Page 12-3). See following NOTE.
NOTE: Brushes must be removed to avoid damage from commutator removal. Lift the brush springs out of
the notches in the brushes and pull the brushes back from the center of the commutator end cover.
The springs will help prevent them from sliding back towards the center (Figure 12-7, Page 12-4).
2. Remove nut (41), lock washer (40), pulley (39), shaft key (34), spacer (37), and bearing retainer screws
(43) and separate armature (33) from output end cover (36) (Figure 12-8, Page 12-5).
Bearing Cleaning and Inspection
1. Wipe the carbon dust from the two bearings. Inspect bearings by spinning them by hand and checking
for both axial (A) and radial (B) play (Figure 12-9, Page 12-5).
2. Replace the bearing if it is noisy, does not spin smoothly, or has excessive play. Replace if rusted, worn,
cracked, or if there is an abnormal color change in the metal of the bearing. Replace if there is extensive
wear or pitting on the balls or rolling surfaces. Do not remove bearings unless they are to be replaced.
Page 12-4 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
Figure 12-7 Pull Brushes Away from Center of the Commutator End Cover
BRUSH BEING HELD
BY BRUSH SPRING
Starter/Generator