Subaru Legacy III (2000-2003 year). Manual - part 297

SC(H6DO)-12

STARTING/CHARGING SYSTEMS

STARTER

6. SWITCH ASSEMBLY OPERATION

1) Connect the terminal S of switch assembly to
positive terminal of battery with a lead wire, and
starter body to ground terminal of battery. The pin-
ion should be forced endwise on shaft.

CAUTION:
With the pinion forced endwise on shaft, starter
motor can sometimes rotate because current
flows, through pull-in coil, to motor. This is not
a problem.
2) Disconnect the connector from terminal M, and
then connect the positive terminal of battery and
terminal M using a lead wire and ground terminal to
starter body.
In this test set up, the pinion should return to its
original position even when it is pulled out with a
screwdriver.

7. PINION GAP

1) Measure pinion gap while the pinion is pulled out
as shown in the figure.

Pinion gap:

0.5 — 2.0 mm (0.020 — 0.079 in)

If the motor is running with the pinion forced end-
wise on shaft, disconnect the connector from termi-
nal M of switch assembly, and then connect
terminal M to ground terminal (

−

) of battery with a

lead wire. Next, gently push the pinion back with
your fingertips, and then measure the pinion gap.
2) If the pinion gap is outside specified range, re-
move or add number of adjustment washers used
on the mounting surface of switch assembly until
correct pinion gap is obtained.

(A) Terminal S

(B) Terminal M

SC-00160

( A )

( B )

(A) Pinion

(B) Gap

SC-00027

( A )

( B )

( C )

SC(H6DO)-13

STARTING/CHARGING SYSTEMS

STARTER

8. PERFORMANCE TEST

The starter should be submitted to performance
tests whenever it has been overhauled, to assure
its satisfactory performance when installed on the
engine.
Three performance tests, no-load test, load test,
and lock test, are presented here; however, if the
load test and lock test cannot be performed, carry
out at least the no-load test.
For these performance tests, use the circuit shown
in figure.

1) No-load test
With switch on, adjust the variable resistance to ob-
tain 11 V, take the ammeter reading and measure
the starter speed. Compare these values with the
specifications.

No-load test (Standard):

Voltage / Current

11 V / 90 A max.

Rotating speed

2,400 rpm or more

2) Load test
Apply the specified braking torque to starter. The
condition is satisfactory if the current draw and
starter speed are within specifications.

Load test (Standard):

Voltage / Load

7.7 V / 16.0 N·m (1.63 kgf-m, 11.8 ft-lb)

Current / Speed

400 A / 740 rpm or more

3) Lock test
With starter stalled, or not rotating, measure the
torque developed and current draw when the volt-
age is adjusted to the specified voltage.

Lock test (Standard):

Voltage / Current

3.5 V / 940 A or less

Torque

28.9 N·m (2.95 kgf-m, 21.3 ft-lb) or more

(A) Variable resistance

(B) Magnetic switch

SC-00077

(A)

(B)

(C)

12V

SC(H6DO)-14

STARTING/CHARGING SYSTEMS

GENERATOR

3. Generator

A: REMOVAL

1) Disconnect battery ground cable.

2) Disconnect connector and terminal from genera-
tor.

3) Remove V-belt. <Ref. to ME(H6DO)-28, RE-
MOVAL, V-belt.>
4) Remove bolt (A), and loosen bolt (B). Then, re-
move generator from bracket.

B: INSTALLATION

Install in the reverse order of removal.

C: DISASSEMBLY

1) Remove the four through-bolts.

2) Heat the portion (A) of rear cover to 50

(122

F) with heater drier.

3) Then insert the tip of a flat tip screwdriver into the
gap between stator core and front cover. Pry them
apart to disassemble.

FU-00009

SC-00140

SC-00141

( A )

( B )

(A) Screwdriver

SC-00142

SC-00078

SC-00079

(A)

SC-00080

(A)

SC(H6DO)-15

STARTING/CHARGING SYSTEMS

GENERATOR

4) Hold the rotor with a vise and remove pulley nut.

CAUTION:
When holding the rotor with vise, insert alumi-
num plates or wood pieces on the contact sur-
faces of vise to prevent rotor from damage.

5) Remove the ball bearing as follows.

(1) Remove the bolt, and then remove the bear-
ing retainer.

(2) Firmly install an appropriate tool (such as a
fit socket wrench) to bearing inner race.

(3) Push the ball bearing off the front cover us-
ing a press.

6) Remove the bearing from rotor using a bearing
puller.

7) Unsolder connection between rectifier and stator
coil to remove the stator coil.

CAUTION:
Do not allow the 180 — 270 W solding bit to con-
tact the terminals for more than 5 seconds at a
time because the rectifier cannot withstand
heat very well.

(A) Front cover

(B) Pulley

(D) Rotor

SC-00035

( A )

( B )

( C )

( D )

SC-00036

SC-00081

SC-00082

SC-00046

SC-00083

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