Pioneer 1200 Maintenance Service Manual page 175

ELECTRICAL COMPONENTS: FE400 ENGINE
Commutator Cleaning and Inspection
1. Clean the carbon dust, dirt and oil from the commutator. Slight roughness of the commutator can be pol-
ished away with 400 grit (or finer) sandpaper. See following CAUTION.
CAUTION
• Never use emery cloth on the commutator. Particles of emery are conductive and may short-
circuit the commutator bars. Never use oil or lubricants on the commutator or brushes.
2. Use a micrometer and measure the outside diameter at four points: two points 90° to each other to the
outside end of the commutator (A
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mutator (B and B ). If the commutator diameter is less than 1.535 inches (39 mm) at any of the four loca-
tions, replace the armature assembly and bearings (Figure 12-12, Page 12-7).
Measure each position
in 2 places, 90° apart.
1
A
2
A
Figure 12-12 Inspect Commutator
Armature Ground Test
CAUTION
• Do not submerge armature in solvent.
NOTE: Before testing, wipe the armature with a clean cloth and remove carbon dust and metal particles
from between commutator bars.
1. Use a multimeter set on 200 Ω (ohms) and place the positive (+) probe on the commutator bars and the
negative (–) probe on the armature core. The reading should be no continuity. If the reading is incorrect,
replace the armature and the two bearings (Figure 12-13, Page 12-8).
Visual Inspection of Field Coils
Burned, blackened, charred, or scorched coil insulation indicates the starter/generator has overheated due to
overloads, grounding, or shorted coil windings and should be replaced. Be sure the insulators are tight in the
housing.
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
1 2
and A ), and two points 90° to each other to the inside of the com-
1
A
A
1
B B
1
1
12
Starter/Generator
Page 12-7