ELECTRICAL COMPONENTS
Starter/Generator
2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 12-3
12
4. Remove the mounting/adjustment nut (12), washer (9) and bolt (11). Lower the starter/generator and
slip the belt (4) off the pulley (10).
5. Support the starter/generator so that when the pivot bolts are removed the starter/generator will not fall
to the ground. Remove the two pivot nuts (7) and bolts (5) from the mounting bracket.
6. Remove the starter/generator.
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 12-4). See following NOTE.
NOTE: If the brushes are not removed, contact between the brushes and commutator as the commutator
end cover is being removed or installed could damage the brushes. 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 rest on the sides of the brushes and help prevent them from sliding towards the center of
the cover (Figure 12-7, Page 12-5).
2. Remove brush covers (29 and 30), screws (25) and lockwashers (26), brush springs (28), and brushes
(27) (Figure 12-4, Page 12-4). 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 12-6.
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 of an inch (1.6 mm)
of the wear line, replace all four brushes (Figure 12-5, Page 12-4).
Figure 12-2 Starter/Generator Removal
5
11
4
9
12
1
10
F2
DF
7
2
13
TO BATTERY
GROUND POST
F1
TERMINAL
14
A2
TERMINAL
A1 TERMINAL
