Pioneer 1200 Maintenance Service Manual page 170

12
ELECTRICAL COMPONENTS: FE400 ENGINE
A1 TERMINAL
13
Disassembly of the Starter/Generator to Service the Brushes
1. Remove the two bolts (20) and pull commutator end cover (23) free of 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 brush covers (29 and 30), screws (25), lock washers (26), brush springs (28), and brushes (27)
(Figure 12-4, Page 12-3). See following NOTE.
NOTE: To clean and inspect the armature/commutator and the bearings, see Disassembly of the
Starter/Generator to Service the Armature/Commutator on page 12-4.
Brush Inspection and Replacement
1. Visually inspect brushes. Replace brushes that are cracked or severely chipped.
2. Check the wear line on the side of the brush. If the end of the brush is within 1/16-inch (1.6 mm) of the
wear line, replace all four brushes (Figure 12-5, Page 12-3).
Brush Spring Inspection and Replacement
1. Visually inspect springs. Replace all four springs if any spring is discolored from heat (straw or bluish in
color).
2. Install the four brushes (27) into their holders and insert the four brush springs (28) (Figure 12-4,
Page 12-3). Test brush spring tension with a spring scale. If any spring has a tension less than 24 ounces
(6.67 N), replace all four springs (Figure 12-6, Page 12-3). See following CAUTION.
Page 12-2 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
F1
A2
TERMINAL
TERMINAL
14
TO BATTERY
GROUND POST
Figure 12-2 Starter/Generator Removal
1
12 9
11
Starter/Generator
5 2
7
10
4