ELECTRICAL COMPONENTS
Starter/Generator
Page 12-4 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual
12
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
12-4). Using a spring scale, test brush spring tension. If any spring has a tension less than 24 ounces,
replace all four springs (Figure 12-6, Page 12-5). See following CAUTION.
∆ CAUTION
• When checking brush spring tension, do not push springs beyond the point they would normally be if
there were new brushes installed. Exerting excessive force or pushing brush springs beyond their
normal maximum extension point will damage springs.
Starter/Generator Assembly
1. Connect the brush wires to the holders using four lockwashers (26) and four screws (25), making sure
the crossover leads are connected also. Tighten the screws to 31 in-lb (3.5 N·m) (Figure 12-4, Page 12-4).
Figure 12-3 Commutator End Cover
Figure 12-4 Brush Covers and Brushes
Figure 12-5 Inspect Brushes
20
23
24
26
27
29
23
TYPICAL
3 PLACES
25
TYPICAL
4 PLACES
30
28
0
1
1/2
1/2
STARTER/GENERATOR
BRUSH
WEAR LINE
BRUSH
HOLDER
