Starting System: Other Mazda 6 GG

Armature

1. Verify that there is no continuity between the commutator and the core at each segment using an ohmmeter. If there is continuity, replace the armature. (Scheme 10)
2. Verify that there is no continuity between the commutator and the shaft using an ohmmeter. If there is continuity, replace the armature. (Scheme 11)
3. Place the armature on V-blocks, and measure the runout using a dial indicator. Maximum runout is 0.002" (0.05 mm). If runout is not within specification, repair using a lathe or replace the armature. (Scheme 12)
4. Measure the commutator diameter. If not within the minimum specification, standard commutator diameter 1.16" (29.4 mm), minimum commutator diameter 1.13" (28.8 mm), replace the armature. (Scheme 13)
5. Measure the segment groove depth of commutator. If not within the minimum specification, undercut the grooves to the standard depth. Standard depth is 0.016-0.023" (0.4-0.6 mm), minimum depth 0.008" (0.2 mm). (Scheme 14)

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Magnetic Switch

1. Inspect for continuity between terminals (S) and (M) using an ohmmeter. If there is no continuity, replace the magnetic switch. (Scheme 15)
2. Inspect for continuity between terminal (S) and the body using an ohmmeter. If there is no continuity, replace the magnetic switch. (Scheme 16)
3. Verify that there is no continuity between terminals (M) and (B) using an ohmmeter. If there is continuity, replace the magnetic switch. (Scheme 17)

Scheme 15

Scheme 16

Scheme 17

Brush & Brush Holder

1. Verify that there is no continuity between each insulated brush and the plate using an ohmmeter. If there is continuity, replace the brush holder. (Scheme 18)
2. Measure the brush length. If any brush is worn almost to or beyond the minimum specification, replace all the brushes. Standard brush length is 0.48" (12.3 mm). The minimum brush length is 0.28" (7.0 mm). (Scheme 19)
3. Measure the brush spring force using a spring balance. If not within the minimum specification, replace the brush spring. Standard spring force is 4.84 ft. lbs. (21.6 N.m) The minimum spring force is 1.3 ft. lbs. (5.9 N.m). (Scheme 20)

Scheme 18

Scheme 19

Scheme 20

2003

For starter wiring diagram, see STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article.

2004

For starter wiring diagram, see STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article.