Mazda RX7. Manual - part 14

STARTER - HITACHI/MITSUBISHI

Article Text (p. 4)

1983 Mazda RX7

For www.iluvmyrx7.com

Sunday, August 26, 2001 03:31PM

1) Apply 12 volts between "M" (MT) terminal and the solenoid
case. Pull pinion out and release it (push plunger into solenoid body
by hand). See Fig. 3.

Fig. 3: Connections for Conducting Return Test
Connect battery to "M" terminal and solenoid case.

2) If the case is short-circuited, the pinion will remain
out (plunger will be attracted). If nothing happens, solenoid is good.

REMOVAL & INSTALLATION

1) On all models, remove negative battery cable. If
necessary raise vehicle on hoist. Remove starter mounting bolts.
Remove starter from vehicle.
2) To install, reverse removal procedure.

OVERHAUL

DISASSEMBLY

NOTE: Procedures may vary slightly between conventional and
reduction gear starters.

1) Loosen nut securing connecting plate-to-magnetic switch
"M" terminal. Remove screws securing magnetic switch and remove
switch (solenoid) assembly. Remove through bolts and brush cover
assembly. Tap yoke assembly loose with wooden mallet. Remove yoke,
armature assembly and pinion shift lever.
2) Remove pinion stop ring from end of armature shaft by
pushing stop ring to clutch side. Remove snap ring and overrunning
clutch assembly from armature shaft.

CLEANING & INSPECTION

STARTER - HITACHI/MITSUBISHI

Article Text (p. 5)

1983 Mazda RX7

For www.iluvmyrx7.com

Sunday, August 26, 2001 03:31PM

Clean all parts. Do not use grease dissolving solvent on
overrunning clutch, armature assembly, solenoid assembly or field
coils due to possible damage. Inspect all parts for damage or wear
and replace as required.

BENCH TESTS

Brushes & Springs
Check brush spring tension using a spring scale. Check brush
contact surface condition and brush length. Check lead clip and wire
connections and condition of brush holders. Replace as required. See
Brush Spring Tension and Minimum Brush Length Charts.

BRUSH SPRING TENSION TABLE

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Application Ozs. (g)

Mazda
B2000 & B2200 Pickups ........... 50-62 (1415-1766)
RX7 ............................. 50-92 (1415-2604)
All Other Models ................ 46-60 (1302-1700)

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MINIMUM BRUSH LENGTH TABLE

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Application In. (mm)

Mazda .................................... .45 (11.5)

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Armature
Check external condition of armature for scoring or other
damage. Measure shaft distortion with dial indicator. Replace
armature if shaft distortion exceeds .004" (.10 mm).

Commutator
1) Inspect commutator for roughness, grooves, burns or
pitting. Sand lightly with 500 grit sandpaper if necessary. Check
commutator for out-of-round and mica insulators undercut to a depth
of .020-.031" (.5-.8 mm).
2) If necessary, commutator may be turned less than .04" (1
mm) from original size and mica undercut. Replace if excessively worn.

Field Coil
1) Check field coil continuity by connecting test probe of
circuit tester or an ohmmeter to the field coil positive terminal and
brush holder. If circuit is open, replace field coil.
2) Check for grounding of field coils by placing one probe
of circuit tester on starter housing and other probe to field coil
positive terminal. If little or no resistance, field coil is grounded
and must be replaced.

STARTER - HITACHI/MITSUBISHI

Article Text (p. 6)

1983 Mazda RX7

For www.iluvmyrx7.com

Sunday, August 26, 2001 03:31PM

Overrunning Clutch Assembly
1) Inspect pinion assembly and sleeve. Sleeve should slide
freely on armature shaft and spline. If damage or resistance is
noted, replace assembly.
2) Check pinion and flywheel teeth for excessive rubbing or
damaged teeth. Replace as required.

Pinion Gear Clearance
1) The clearance between the pinion gear and pinion stopper
collar should be .012-.098" (.3-2.5 mm) on Hitachi starters, or
.02-.08" (.51-2.03 mm) on Mitsubishi starters, when solenoid is
engaged. Adjust as necessary by changing shims between solenoid and
starter yoke.
2) On Mazda B2200 models, projection distance (starter
housing-to-front face of gear) should be .67" (17 mm). On Mazda RX-7
models, projection should be 1.06" (27.5 mm).

Pinion Case Bearing
Inspect bearing for wear and check side play. If clearance
exceeds .008" (.2 mm), replace bearing. New bearing clearance should
be .001-.004" (.025-.10 mm) for Hitachi or .002-.004" (.05-.10 mm)
for Mitsubishi starters.

NOTE: Ensure that bearing is installed so that end of bearing is
flush with gear case end.

REASSEMBLY

To reassemble, reverse disassembly procedure. Fill gear case
on reduction gear models with grease. Lightly oil pinion and all
bearing surfaces.

Fig. 4: Measuring Pinion Edge-to-Pinion Stopper Clearance

STARTER - HITACHI/MITSUBISHI

Article Text (p. 7)

1983 Mazda RX7

For www.iluvmyrx7.com

Sunday, August 26, 2001 03:31PM

Fig. 5: Disassembled View of Typical Mitsubishi Conventional Starter

END OF ARTICLE

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