Mitsubishi Colt Ralliart. Manual - part 123

 

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Mitsubishi Colt Ralliart. Manual - part 123

 

 

STARTING SYSTEM

ENGINE ELECTRICAL

16-26

CAUTION

This test must be performed quickly (in less than 
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the M-terminal 

and body.

WARNING

Be careful not to get your fingers caught 
when pulling out the pinion.

3. Pull the pinion out and release. If the pinion 

quickly returns to its original position, everything is 
operating properly. If it doesn't, replace the starter 
motor.

<CVT>
PINION GAP ADJUSTMENT

AK305042AB

Switch

S

M

Wire

Battery

Starter
motor

B

1. Disconnect the field coil wire from the M-terminal 

of the magnetic switch.

2. Connect a 12-volt battery between the S-terminal 

and M-terminal.

CAUTION

This test must be performed quickly (in less than 
10 seconds) to prevent the coil from burning.
3. Set the switch to "ON", and the pinion will move 

out.

AKX00198

Stopper

Pinion gap

Pinion

AC

4. Check the pinion-to-stopper clearance (pinion 

gap) with a feeler gauge.

Standard value: 0.5 

− 2.0 mm

AKX00199

5. If the pinion gap is out of specification, adjust by 

adding or removing gasket(s) between the 
magnetic switch and front bracket.

MAGNETIC SWITCH PULL-IN TEST

AK305043AB

S

M

Wire

Battery

Starter
motor

B

1. Disconnect the field coil wire from the M-terminal 

of the magnetic switch.

CAUTION

This test must be performed quickly (in less than 
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal 

and M-terminal.

3. If the pinion moves out, the pull-in coil is good. If it 

doesn't, replace the magnetic switch.

MAGNETIC SWITCH HOLD-IN TEST

AK305044AB

S

M

Wire

Battery

Starter
motor

B

1. Disconnect the field coil wire from the M-terminal 

of the magnetic switch.

Main

Index

Group

TOC

STARTING SYSTEM

ENGINE ELECTRICAL

16-27

CAUTION

This test must be performed quickly (in less than 
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal 

and body.

3. Manually pull out the pinion as far as the pinion 

stopper position.

4. If the pinion remains out, everything is in order. If 

the pinion moves in, the hold-in circuit is open. 
Replace the magnetic switch.

FREE RUNNING TEST

AK305045AB

S

A

M

V

B

Carbon-pile rheostat

Battery

Voltmeter

Ammeter

Starter
motor

1. Place the starter motor in a vise equipped with 

soft jaws and connect a fully-charged 12-volt 
battery to the starter motor as follows:

2. Connect a test ammeter (100-ampere scale) and 

carbon pile rheostat in series between the battery 
(+) terminal and starter motor terminal.

3. Connect a voltmeter (15-volt scale) across the 

starter motor.

4. Rotate the rheostat to full-resistance position.
5. Connect the battery cable from the battery (-) 

terminal to the starter motor body.

6. Adjust the rheostat until the battery voltage shown 

on the voltmeter is 11 V.

7. Confirm that the maximum amperage is within the 

specifications and that the starter motor turns 
smoothly and freely.

Current: 

maximum 95 Amps

MAGNETIC SWITCH RETURN TEST

AK305046AB

S

M

Wire

Battery

Starter
motor

B

1. Disconnect the field coil wire from the M-terminal 

of the magnetic switch.

CAUTION

This test must be performed quickly (in less than 
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the M-terminal 

and body.

WARNING

Be careful not to get your fingers caught 
when pulling out the pinion.

3. Pull the pinion out and release. If the pinion 

quickly returns to its original position, everything is 
operating properly. If it doesn't, replace the 
magnetic switch.

STARTER MOTOR ASSEMBLY INSPECTION <4G1>

M1162001100498

MAGNETIC SWITCH PULL-IN TEST

AK305703

B

M

S

Battery

Starter 
motor

AC

Wire

1. Disconnect the field coil wire from the M-terminal 

of the magnetic switch.

CAUTION

This test must be performed quickly (in less than 
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal 

and M-terminal.

3. If the pinion moves out, the pull-in coil is good. If it 

doesn't, replace the starter motor.

Main

Index

Group

TOC

STARTING SYSTEM

ENGINE ELECTRICAL

16-28

MAGNETIC SWITCH HOLD-IN TEST

AK305704

B

M

S

Battery

Starter 
motor

AD

Wire

1. Disconnect the field coil wire from the M-terminal 

of the magnetic switch.

CAUTION

This test must be performed quickly (in less than 
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal 

and body.

3. Manually pull out the pinion as far as the pinion 

stopper position.

4. If the pinion remains out, everything is in order. If 

the pinion moves in, the hold-in circuit is open. 
Replace the starter motor.

FREE RUNNING TEST

AK305705

S

M

B

Ammeter

Carbon-pile
rheostat

Battery

Starter
motor

Voltmeter

AB

A

V

1. Place the starter motor in a vise equipped with 

soft jaws and connect a fully-charged 12-volt 
battery to the starter motor as follows:

2. Connect a test ammeter (100-ampere scale) and 

carbon pile rheostat in series between the battery 
(+) terminal and starter motor terminal.

3. Connect a voltmeter (15-volt scale) across the 

starter motor.

4. Rotate the rheostat to full-resistance position.
5. Connect the battery cable from the battery (-) 

terminal to the starter motor body.

6. Adjust the rheostat until the battery voltage shown 

on the voltmeter is 11.5 V.

7. Confirm that the maximum amperage is within the 

specifications and that the starter motor turns 
smoothly and freely.

Current: 

maximum 40 Amps

MAGNETIC SWITCH RETURN TEST

AK305706

B

M

S

Battery

Starter 
motor

AC

Wire

1. Disconnect the field coil wire from the M-terminal 

of the magnetic switch.

CAUTION

This test must be performed quickly (in less than 
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the M-terminal 

and body.

WARNING

Be careful not to get your fingers caught 
when pulling out the pinion.

3. Pull the pinion out and release. If the pinion 

quickly returns to its original position, everything is 
operating properly. If it doesn't, replace the starter 
motor.

Main

Index

Group

TOC

STARTING SYSTEM

ENGINE ELECTRICAL

16-29

DISASSEMBLY AND ASSEMBLY

M1162001200451

AK201881

14

12

11

20

1

15

16

17

18

19

13

10

2

4

3

5

7

6

8

9

AG

Disassembly steps 

1. Screw

<<

A

>>

2. Magnetic switch
3. Screw
4. Bolt
5. Rear bracket
6. Brush holder
7. Rear bearing
8. Armature
9. Yoke assembly
10. Packing A

11. Packing B
12. Plate
13. Planetary gear
14. Lever

<<

B

>> >>

A

<< 15. Snap ring

<<

B

>> >>

A

<< 16. Stop ring

17. Overrunning clutch
18. Internal gear
19. Planetary gear shaft
20. Front bracket

Disassembly steps (Continued)

Main

Index

Group

TOC

 

 

 

 

 

 

 

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