103862-0322 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1038620322

A starting motor solenoid that will not operate may not be receiving battery current. Attach one lead of the voltmeter to the solenoid battery cable connection. Ground the other lead. No voltmeter reading indicates a faulty circuit from the battery. A voltmeter reading indicates further testing is necessary. Continue the test by attaching one voltmeter lead to the starting motor solenoid small wire terminal and the other lead to ground. Observe the voltmeter and turn the HEAT-START switch to START. A voltmeter reading indicates that the malfunction is in the solenoid. No voltmeter reading indicates that either the series-parallel switch is the fault or the HEAT-START switch does not close when turned to the START position. Attach one lead of the voltmeter to the HEAT-START switch battery wire terminal and ground the other lead. A voltmeter reading indicates a defective switch. No voltmeter reading indicates further testing of the series-parallel switch is necessary. A starting motor that operates too slow can be overloaded by excessive mechanical friction within the engine being started. Slow starting motor operation can also be caused by shorts, loose connections and/or excessive dirt within the motor. PINION CLEARANCE ADJUSTMENT: Whenever the solenoid is installed, the pinion clearance should be adjusted. The adjustment should be made with the starting motor removed.Bench test and adjust the pinion clearance at installation of solenoid as follows:
CIRCUIT FOR CHECKING AND ADJUSTING PINION CLEARANCE1. Install the solenoid without connector from the MOTOR terminal on solenoid to the motor.2. Connect a battery, of the same voltage as the solenoid, to the terminal marked SW.3. Connect the other side of battery to ground terminal or to solenoid frame.
CHECKING PINION CLEARANCE
ADJUSTING PINION CLEARANCE4. MOMENTARILY flash a jumper wire from the solenoid terminal marked MOTOR to the frame or ground terminal. The pinion will shift into cranking position and will remain there until the battery is disconnected.5. Push pinion towards commutator end to eliminate free movement.6. Pinion clearance should be .36 in. (9,14 mm).7. Adjust clearance by removing plug and turning shaft nut.General Reconditioning
Approximately every 200,000 miles, the starter should be removed so that it may be completely disassembled, washed and have all parts replaced that show evidence of being unsatisfactory for reason of wear. Do not use a degreaser or high temperature cleaning method when cleaning parts of the starter.No periodic service is indicated for the electric starter brushes between general reconditioning periods. The brushes should only be inspected after removal of the starter from the engine and removal of the commutator end bearing frame. The electric starter commutator end and drive end bearings are equipped with wicks for lubrication purposes. The wicks should be saturated with oil whenever the electric starter is removed or disassembled. It is suggested that cleaning and reconditioning be entrusted to your authorized dealer.Glow Plugs
TESTING GLOW PLUGS: Glow plugs can be checked with an ammeter. Disconnect the wire lead from the glow plug terminal on the HEAT-START switch. Install an ammeter, in series, between the disconnected lead and