Dadi. Engine 4G64 S4M. Service Manual - part 5

11-59

ENGINE

 AC GENERATOR

wear limit line wite

9EN0192

9EN0193

9EN0194

6EN1706

steel wirt

6EN1705

rear cap

brush

steel wirt

BRUSH

(1)

If the brush is worn out to the wear limit line, replace brush by

taking the following steps:

(2)

The brush may be taken off by burning off the soldering joint of

the brush lead-wire.

(3)

While mounting new brush, you should burn on the brush lead-

wire with the brush being pressed into the brush holder.

NOTES FOR ASSEMBLY

MOUNTING OF ROTOR

(1)

Before mounting the rotor onto the rear cap, insert a steel wire

into the small hole on the rear cap to lift the mounted rotor, and

then pull out the steel wire.

A

11-60

ENGINE

 STARTER

Disassembly Process

1.

bolt

2.

magnet valve

3.

bolt

4.

bolt

5.

rear carrier

6.

brush holder

7.

brush

8.

rear bearing

9.

rotor

10. yoke assembly

11. washer A

12. washer B

13. plate

14. ball

15. planetary gear

16. rod

17. snap spring

18. checking ring

19. free engine clutch

20. inner gear

21. planetary gear carrier

22. front carrier

STARTER

DISASS0.EMBLY AND ASSEMBLY

1

17

16

13

12

21

2

11

14

15

4

5

3

9

10

7

6

22

18

19

6EN1412

A

C

A

C

A

B

B

11-61

ENGINE

 STARTER

1EN0298

6EN0612

snap spring clamp

pinion

free engine clutch

rotor

depth

dinion

snap spring clamp

rotor

checking ring

casing tube

snsp spring

6EN0611

magnetic switch

terminal S

terminal

exciting coil

wiring

6EN0616

terminal B

ESSENTIALS FOR DISASSEMBLY

DISASSEMBLY OF MAGNET VALVE

(1)

Knock down exciting coil from terminal M of the magnet valve.

DISASSEMBLY OF ROTOR AND BALL

(1)

Do not drop the ball mounted on the end of bearing while

disassemble the rotor.

DISASSEMBLY OF SNAP SPRING AND CHECKING

RING

(1)

Push and press the checking ring to the free engine clutch with a

proper casing tube to separate it from the snap spring.

(2)

Dismantle the snap spring with a snap spring clamp first, then

disassemble the checking ring and free engine clutch.

CLEANING OF STARTER COMPONENTS

(1)

Don

t clean the components in detergent. Immerging the yoke

and exciting coil assembly or rotor into detergent may damage

their insulation property.

(2)

When these components are contaminated, use a piece of cloth to

clean them.

(3)

The driving parts may neither be immerged into detergent.

Because free engine clutches have been lubricated before leaving

factory, if you clean them in detergent, the lubricant inside the

clutch may be washed off.

(4)

The driving part should be cleaned with a brush dipped with

detergent, and toweled off with cloth.

CHECK

COMMUTATOR

(1)

Put the rotor on a pair of V-blocks, check its radial jumping with

a dial gage.

Standard value: 0.5mm

Limit value: 0.1mm

A

B

C

11-62

ENGINE

 STARTER

(2)

Check the outside diameter of the . commutator

Standard value: 29.4mm

Limit value: 28.4mm

(3)

Check the drop depth of mica between commutator separators.

Standard value: 0.5mm

Limit value: 0.2mm

BRUSH HOLDER

(1)

Check whether conduction exists between brush holder plate and

brush holder, if not, it is normal.

FREE ENGINE CLUTCH

(1)

Confirm that the pinion is resisted when rotating to the left while

smoothly rotated when turning right.

(2)

Check the wearing and damages of the pinion.

BRUSH

(1)

Check the roughness of the contact surface of brush and commu-

tator and the length of brush.

Limit value: Wear limit mark

(2)

While rectifying the contact surface or changing new brush, you

may wrap a piece of sand paper around the commutator.

1EN0298

1EN0296

depth

brush holder

mica

6EN0602

brush holder

slacken

fasten

6EN1777

wear limit mark

6EN1778

11-63

ENGINE

 STARTER

(3)

While crumbing worn battery with a plier, be careful not to

damage the soft pigtail.

(4)

In order to make soldering tin easy to be adhered, scrape the soft

pigtail end with a piece of sand paper.

(5)

Insert soft pigtail into the new brush hole and burn it on and be

sure no soldering tin exposed on the surface of brush.

DETECT SHORT CIRCUIT OF ROTOR WINDING

(1)

Put the rotor onto the growler.

(2)

Place the tagger above the rotor and keep it parallel to the central

axis of the rotor, slowly rotate the rotor and observe the tagger.

If it is not magnetized and doesn

t viberate, the rotor is normal.

NOTES:

CONDUCTING DETECTION AFTER COMPLETELY

CLEANING THE SURFACE OF ROTOR.

(3)

Check the insulation between commutator separators and the

iron core of rotor. If conduction fails, it

s normal.

DETECT OPEN CIRCUIT OF WROTOR INDING

(1)

Check whether conduction exists between all commutator

segment, if yes, its normal.

NOTES FOR ASSEMBLY

MOUNTING OF CHECKING RING AND SNAP

SPRING

(1)

Use a proper tool to pull the checking ring from across the snap

spring towards it.

soft pigtail

new brush

sodering (no
soldering tin
exposed on the
surface of brush)

mark

1EN0285

growler

6EN1779

6EN1780

1EN0299

checking ring

checking ring

6EL0099

A

snap spring

11-64

ENGINE

 THROTTLE BODY

THROTTLE BODDY

DISASSEMBLY AND ASSEMBLY

Disassembly Procedure

1.

holder

2.

throttle position transducer

3.

idle air valve

4.

o-ring

5.

throttle body

6.

SAS speed adjusting screw SAS

CLEANING OF THROTTLE BODY

COMPONENTS

1. Clean all throttle body components.

Don

t use detergent to clean the following components:

 Throttle position transducer

 Idle speed control body assembly

If these components are immerged into detergent, their

insulation property will be damaged.

Only cloth may be used to clean them.

Remarks

1. SAS has been adjusted before leaving factory, so no

adjustment is needed.

2. In case the fixed SAS is dismantled by chance, the speed

adjusting screw of throttle should be fixed up again.

3. In case the throttle speed adjusting screw is dismantled by

chance, it should be readjusted.

2. Check whether the vacuum port or passage is

jammed. Clean the vacuum passage with com-

pressed air.

6EN1782

4.9N.m

3.4N.m

2.9N.m

3.4N.m

3

1

4

6

2

5

N