Pioneer 1200 Maintenance Service Manual page 177

ELECTRICAL COMPONENTS: FE400 ENGINE
∆
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 12-6).
4. Slide the bearing retainer onto the output end of the armature shaft (33) so that it will hold only the outside
of the bearing (35) (Figure 12-8, Page 12-5).
5. Press a new ball bearing (35) onto the output end of the armature. Press a new ball bearing onto the com-
mutator end of the armature shaft. See following CAUTION.
∆
CAUTION
• Use care while pressing new bearing onto the output end of the shaft to prevent damage to
the retainer.
• 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 12-5).
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. Install the commutator. Lift the brush springs out of the notches in the brushes and pull the brushes back
from the center of the commutator end cover to avoid interfearance. The springs will rest on the sides of
the brushes and help prevent them from sliding to the center of the cover (Figure 12-7, Page 12-4).
9. Install the commutator end cover (23) onto the armature shaft. Align the locating pin and 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 12-3).
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) onto the openings in the commutator end cover (23) (Figure 12-4, Page 12-3).
11. Slide the spacer (37) onto the end of the shaft. Insert the shaft key (34) into the shaft. Install the belt pul-
ley (39) onto the shaft, and install the lock washer (40) and M14 nut (41) and tighten the nut to 28 ft-lb
(38 N·m) (Figure 12-8, Page 12-5).
Starter/Generator Installation
1. Install the green wire from the F1 terminal to the A1 terminal on the starter/generator (Figure 12-2,
Page 12-2). Install a flat washer, lock washer, and nut onto each terminal and tighten to 48 in-lb (5.4
N·m).
2. Install two 3/8-inch 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 lock nut (7) onto
each bolt and tighten to finger-tight (Figure 12-14, Page 12-10).
3. Install the adjustment bolt (11) through the adjusting bracket (4) and then through the starter/generator.
Install a lock washer (9) and 5/16-inch nut (12) onto the end of the adjustment bolt (11) and tighten to fin-
ger-tight (Figure 12-14, Page 12-10).
4. Install the belt (3), then tighten the mounting bolts. See Belt Tension Adjustment on page 12-10.
5. Connect the yellow wire from the voltage regulator to the DF terminal on the starter/generator. Install a
flat washer, lock washer, and nut onto the terminal and tighten the nut to 31 in-lb (3.5 N·m).
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
12
Starter/Generator
Page 12-9