TESTING
WARNING
During the following test, the starter motor must not be energized for longer than 5 seconds, otherwise you run the risk of burning out the starter motor coil.
- Remove the starter motor from the vehicle.
- Detach the field coil lead from terminal M on the starter motor.
- Using jumper wires, connect a 12 volt battery to the starter motor so that the negative battery terminal is attached to the starter motor housing and to solenoid terminal M, and that the positive battery terminal is connected to starter motor solenoid terminal S. The starter motor plunger should move outward; if it does not, replace the solenoid with a new one.
Fig. 1: To test the solenoid plunger, first detach the field coil lead from alternator terminal M, then attach a 12 volt battery to the starter motor as shown . . .
Fig. 2: . . . then detach the negative jumper wire from terminal M. The plunger should remain extended
Fig. 3: Detach the other negative lead from the starter motor housing. The solenoid plunger should now retract to its normal resting position
Fig. 4: Use an ammeter to measure the amount of current draw the stai need to find out - 90882g53.gifses
- Detach the negative battery jumper wire from terminal M on the starter motor solenoid, and check the plunger for movement. The plunger should remain extended; if the plunger returns to its resting position, replace the solenoid with a new one.
- While observing the solenoid plunger, detach the negative battery lead from the starter motor housing. The plunger should return to its normal resting position; if it does not, replace the solenoid with a new one.
- Reattach the 12 volt battery and install an ammeter to the starter motor as shown in the accompanying illustration. The starter motor should rotate smoothly and steadily with the pinion gear moving out, and the ammeter should display less than 60 amps at 11.5 volts (Samurai models), or 90 amps at 11 volts (Sidekick, Tracker, X-90 and Sidekick Sport models). If the ammeter does not display the specified values, or if the starter motor does not operate smoothly and steadily, replace the starter motor with a new one.
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REMOVAL & INSTALLATION
- Disconnect the negative battery cable.
- If necessary for added under-vehicle clearance, apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
- From beneath the vehicle, label and detach all wiring from the starter motor solenoid terminals.
- Remove one of the two starter motor mounting bolts and loosen the other bolt until it can be turned by hand, then support the starter motor with one hand while removing the last starter motor mounting bolt.
- Lower the starter motor down and away from the engine and transmission.
To install:
- Hold the starter motor in position and install the two mounting bolts. Tighten the two bolts securely.
- Reattach all applicable wiring to the starter motor solenoid. Ensure that the wiring terminals and connectors are clean and free of corrosion.
- If necessary, lower the vehicle.
- Connect the negative battery cable.
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