ELECTRICAL COMPONENTS
Starter/Generator
2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual Page 12-11
12
∆ CAUTION
• Route the field terminal wires so that they will not contact the armature.
3. Install the four pole pieces into the housing. Use the four screws to secure pole pieces to the inside of
the housing to retain the field wires. Tighten screws to 9 ft-lb (12.2 N·m) (Figure 12-11, Page 12-8).
4. Slide the bearing retainer onto the output end of the armature shaft (33) so that it will hold the outside
of the bearing (35) only.
5. Press a new ball bearing (35) onto the output end of the armature (Figure 12-8, Page 12-6). Press a
new ball bearing onto the commutator end of the armature shaft. See following CAUTION.
∆ CAUTION
• To prevent damage to the retainer, use care while pressing new bearing onto the output end of the
shaft.
• Press against the inner race of the new bearing until it is fully seated.
6. Install the output end cover (36) onto the armature. Secure the bearing retainer (32) to the cover and
tighten the screws (43) to 39 in-lb (4.4 N·m) (Figure 12-8, Page 12-6).
7. Slide the housing with field coils over the armature. Use the locating pin to align housing to the cover.
NOTE: The terminal insulators should be on the commutator end of the housing.
8. To prevent contact between the brushes and commutator as the commutator cover is installed, and
possible damage to 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).
9. Install the commutator end cover (23) onto the armature shaft. Align the locating pin with the pin hole in
the cover. Install the two M6 x 180 mm bolts (20), and tighten to 100 in-lb (11.3 N·m) (Figure 12-3,
Page 12-4).
10. Push the brushes down into the holders. Place springs into the notches in the brushes. Install the brush
cover (30) that has the drain hole in it next to the A2 terminal. Install the remaining three brush covers
(29) in the openings in the commutator end cover (23) (Figure 12-4, Page 12-4).
11. Slide the spacer (37) onto the end of the shaft. Insert the shaft key (34) into the shaft. Install the belt
pulley (39) onto the shaft, and install the lockwasher (40) and M14 nut (41). Tighten the nut to 28 ft-lb
(38 N·m) (Figure 12-8, Page 12-6).
Starter/Generator Installation
1. Install the green wire from the F1 terminal to the A1 terminal on the starter/generator (Figure 12-2, Page
12-3). Install a flat washer, lockwasher, and nut onto each terminal and tighten to 48 in-lb (5.4 N·m).
2. Install two 3/8 hex head pivot bolts (5) into the mounting bracket with the heads of the bolts facing
towards the driver side of the vehicle. Position the starter/generator in the mounting bracket so that the
bolts will go through the starter/generator before going through the bracket. Install a locknut (7) onto
each bolt. Tighten to finger tight (Figure 12-14, Page 12-12).
