Starters - Evolution: Other Mitsubishi Lancer IX

PINION GAP

1. Disconnect the field coil wire from the "M" terminal of magnetic switch. (Scheme 11)
2. Connect a 12V battery between "S" terminal and "M" terminal.
3. Set switch to ON and pinion will move out.
4. Check the pinion to stopper clearance (pinion gap) with a feeler gauge. (Scheme 12)
5. If the pinion gap is out of specification, adjust by adding or removing gasket (s) between the magnetic switch and front bracket.

Scheme 11

Scheme 12

STARTER MOTOR DOES NOT OPERATE

1. Check the starter (coil).
2. Check for poor connection at the battery terminals and starter.
3. Check starter relay.
4. Check the clutch pedal position switch.

STARTER MOTOR DOES NOT STOP

Check the magnetic switch.

1. Is the battery in good condition? If Yes, go to the next step. If No, then charge or replace battery.
2. Disconnect the starter motor "S" (solenoid) terminal connector. Using a jumper wire, apply battery positive voltage to starter motor "S" (solenoid) terminal. Does starter motor operate normally? If Yes, then check ignition switch, starter relay, clutch pedal position switch and the line between the battery and starter motor "S" (solenoid) terminal. If No, then go to the next step.
3. Check if the cable between starter "B" (battery) terminal and battery positive terminal for connection and continuity. Is the starter cable in good condition? If Yes, then go to the next step. If No, then repair or replace the cable.
4. Check the connection and continuity of the cable between starter motor body and the negative battery terminal. Is the ground line in good condition? If Yes, then go to the next step. If No, then repair or replace cable.
5. Is the starter motor in good condition? If Yes, problem is excessive rotational resistance of the engine. If No, then replace the starter motor.

STARTER RELAY CHECK

For starter relay testing (Scheme 13)

Scheme 13

COMMUTATOR CHECK

1. Place the armature on a pair of V-blocks and check the runout by using a dial gauge. See «STARTER SPECIFICATIONS»(ref-164495-S38994179702004080600000) .
2. Check the outer diameter of the commutator. See «STARTER SPECIFICATIONS»(ref-164495-S38994179702004080600000) .
3. Check the depth of the undercut between segments. See «STARTER SPECIFICATIONS»(ref-164495-S38994179702004080600000) .
4. Replace commutator if runout, diameter or undercut depth is not within specification.

BRUSH HOLDER

1. Push the brush into the brush holder to make sure that the spring is not working on the brush.
2. If the spring is not working, replace the brush holder.

BRUSH CHECK

1. Check the commutator contacting surface of each brush for abnormal roughness. Also check the height of the brush. Replace the brush holder if this measurement exceeds the limit. The minimum limit is .28" (7.0 mm).
2. When the contact surface of the brush is rectified or the brush holder is replaced, recondition the contact surface with sandpaper wrapped around the commutator.

OVERRUNNING CLUTCH

1. Make sure that the pinion cannot be turned counterclockwise and can be turned clockwise freely. (Scheme 14)
2. Check the pinion for abnormal ware and damage.

Scheme 14

ARMATURE COIL CHECK

1. Place armature in a growler. (Scheme 15)
2. While holding a thin strip of iron against the armature in parallel with its axis, turn the armature slowly. The armature is normal if the iron strip is not attract to the armature or it does not vibrate.
3. Check the insulation between commutator segments and armature coils. (Scheme 16) The armature coils are properly insulated if no continuity is present.
4. Check continuity between a segment and another. There is no open circuit in the tested coil if there is continuity. (Scheme 17)

Scheme 15

Scheme 16

Scheme 17

Check Contact Fusion

Check that there is no continuity between the "B" terminal and "M" terminal. (Scheme 18) If there is continuity, replace the magnetic switch.

Scheme 18

Check Switch Contact

Push the indicated end of the magnetic switch with a strong force to close the internal contacts. Without releasing the switch end, check that there is continuity between the "B" terminal and "M" terminal. (Scheme 19) If there is no continuity, replace the magnetic switch.

Scheme 19

Cleaning