Starters - Except Evolution: Other Mitsubishi Lancer IX

PINION GAP

1. Disconnect the field coil wire from the "M" terminal of magnetic switch. (Scheme 28)
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 29)
5. If the pinion gap is out of specification, adjust by adding or removing gasket(s) between the magnetic switch and front bracket.

Scheme 28

Scheme 29

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.
5. Check the theft-alarm starter relay.

STARTER MOTOR DOES NOT STOP

Check 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, park/neutral 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 cable 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 30)

Scheme 30

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-164496-S04902182952004080600000) .
2. Check the outer diameter of the commutator. See «STARTER SPECIFICATIONS»(ref-164496-S04902182952004080600000) .
3. Check the depth of the undercut between segments. See «STARTER SPECIFICATIONS»(ref-164496-S04902182952004080600000) .
4. Replace commutator, if runout, diameter or undercut depth is not within specification.

BRUSH HOLDER CHECK

Check for the continuity between the brush holder plate and the brush holder. (Scheme 31) There should be no continuity.

Scheme 31

BRUSH CHECK

1. Brushes that are worn beyond wear limit line, or oil-soaked, should be replaced.
2. When replacing the ground brush, slide the brush from the brush holder by prying the retaining spring back.

OVERRUNNING CLUTCH

1. While holding the clutch housing, rotate the pinion. The drive pinion should rotate smoothly in one direction, but should not rotate in opposite direction. If the clutch does not function properly, replace the overrunning clutch assembly. (Scheme 32)
2. Inspect the pinion for wear or burrs. If the pinion is worn or burred, replace the overrunning clutch assembly. If the pinion is damaged, also inspect the ring gear for wear or burrs.

Scheme 32

FRONT & REAR BRACKET BUSHING CHECK

Inspect the bushing for wear or burrs. If the bushing is worn or burred, replace the front bracket assembly or rear bracket assembly.

ARMATURE CHECK

1. Check that the armature coil is not grounded.
2. Place the armature in a growler.
3. Hold a thin steel blade parallel and just above the armature while slowly rotating in the growler. A shorted armature will cause a blade to vibrate and be attract to the core. (Scheme 33) Replace the shorted armature.
4. Check the insulation between the armature coil cores and the commutator segments. (Scheme 34) They are normal if there is no continuity.
5. Check for continuity between the segments. (Scheme 35) The condition is normal if there is continuity.

Scheme 33

Scheme 34

Scheme 35

Cleaning