Isuzu N-Series. Manual - part 407

6D2-14 STARTING SYSTEM

2) File away any foreign material clinging to the

edge of the lead wire.

3) Remove the brushes from the brush holder.
4) Install the new brushes.
5) Straighten the bent portion of the clip.

6) File away any foreign material clinging to the

clip surface.

7) Place the lead wire in the clip.
8) Bend the clip shut.
9) Solder the brush lead.

10) Repeat the procedure for each of the brushes.

Overrunning Clutch

1. Inspect the overrunning clutch gear teeth for ex-

cessive wear and damage.
Replace the overrunning clutch if necessary.

2. Rotate the pinion clockwise.

It should turn smoothly.

3. Try to rotate the pinion in the opposite direction.

The pinion should lock.

Ball Bearing

Inspect the bearings for excessive wear and damage.
Replace the bearings if necessary.

N6A1014E

N6A1015E

N6A1016E

N6A1017E

STARTING SYSTEM 6D2-15

Magnetic Switch

The following tests must be performed with the starter
motor fully assembled.
The yoke lead wire must be disconnected from the “C”
terminal.
To prevent coil burning, complete each test as quickly
as possible (within three to five seconds).
Temporarily connect the magnetic switch between the
clutch and the housing and run the following test.
Complete each test within three to five seconds.

1. Pull-Out Test

Connect the battery negative terminal with the
magnetic switch body and the C terminal. When
current is applied to the 50 terminal from the bat-
tery positive terminal, the pinion should flutter.

2. Hold-in Maintenance Test

Disconnect the lead at the C terminal. The pinion
should continue to flutter.

3. Return Test

Connect the battery negative leads to the starter
body and the 50 terminal.

Connect the battery positive lead at the C terminal.
The pinion should return to its home position.

Reassembly

1. Gear Case
2. Magnetic Switch Assembly
3. Torsion Spring
4. Shift Lever

1) Attach the torsion spring to the hole in the mag-

netic switch as illustrated.

N6A1017E

N6A1019E

N6A1020E

N6A1021E

6D2-16 STARTING SYSTEM

2) Insert the shift lever into the plunger hole of the

magnetic switch.

5. Dust Cover

Install the dust cover.

6. Bolt

Install the magnetic switch assembly in the gear
case and tighten the bolt to the specified torque.

Tighten:
Gear case bolt to 8 N

⋅m (0.8 kg⋅m / 69 lb⋅in)

7. Pinion Clutch
8. Pinion Shaft

Apply a coat of grease to the pinion clutch gear and
install the pinion assembly to the armature shaft.

9. Return Spring

10. Pinion Stopper
11. Pinion Stopper Clip
12. Ball Bearing
13. Bearing Holder
14. Clutch Assembly
15. Bearing Retainer
16. Armature
17. Yoke
18. Brush Holder

1) Twist the holder spring and hold it.
2) Install the brush to the brush holder.
3) Repeat step 1 and 2 for the reaming holders.
4) Install the brush holder assembly to the yoke.

N6A1023E

N6A1024E

N6A1025E

N6A1026E

STARTING SYSTEM 6D2-17

Take care not to damage the commutator face
and the brushes.

19. Rear Cover
20. Through Bolt

Install the through bolts in the rear cover and tight-
en them to the specified torque.

Tighten:
Through bolt to 6 N

⋅m (0.6 kg⋅m / 52 lb⋅in)

21. Lead Wire Nut

Connect the lead wire in the magnetic switch and
tighten the terminal nut to the specified torque.

Tighten:
Lead wire terminal nut to 10 N

⋅m (1.0 kg⋅m / 87 lb⋅in)

Pinion Jump-out dimension

• Connect the (+) cable of battery to terminal S and

the (

−) cable to terminal M. Turn the switch on, and

measure pinion travel dimension “L” in thrust direc-
tion from the jump-out position.

In measuring the dimension, pull the pinion out a little in
the arrow direction.

If the measured value is out of standard, adjust the of
shims.

N6A1027E

N6A1028E

Legend

1. Spacer

mm (in)

Dimension

Standard

L

0.3 — 0.1 (0.01 — 0.004)

N6A1029E

N6A1030E