Pinion Clearance Adjustment (Delco-Remy)

ELECTRICAL SYSTEM

TESTING AND ADJUSTING

NOTE: Make reference to Special Instruction

Alternator Regulator (Motorola)

(GEG02276) and to the instructions inside of the cover

of the tester, when testing with the 5P300 Electrical

Tester.

Use a D. C. Voltmeter to find starting system

components which do not function.

Move the starting control switch to activate the

starter solenoid. Starter solenoid operation can be

heard as the pinion of the starter motor is engaged with

the ring gear on the engine flywheel. The solenoid

operation also closes the electric circuit to the motor.

Connect one lead of the voltmeter to the solenoid

connection (terminal) that is fastened to the motor. Put

the other lead to a good ground. Activate the starter

solenoid and look at the voltmeter. A reading of battery

voltage shows the problem is in the motor. The motor

REGULATOR ADJUSTMENT

must be removed for further testing. No reading on the

voltmeter shows that the solenoid contacts do not close.

To make an increase to the voltage (approximately

This is an indication of the need for repair to the

.4 volt on a 12 volt system or .6 volt on a 24 volt

solenoid or an adjustment to be made to the starter

system) remove the locknuts from the two terminals that

pinion clearance. Pinion clearance for Delco-Remy

are nearer the word "HI" than the other terminals. Put

starters is .36 in. (9.1 mm). Pinion clearance for the

the metal strap over these terminals, put the locknuts on

Prestolite starter is .020 to .050 in. (0.51 to 1.27 mm).

the terminals and tighten the locknuts.

If the solenoid for the starting motor will not operate,

To make the voltage lower (approximately .4 volt on

it is possible that the current from the battery is not

a 12 volt system and .6 volt on a 24 volt system) put the

getting to the solenoid.

Fasten one lead of the

metal strap on the two terminals nearer the word "LO".

voltmeter to the connection (terminal) for the battery

cable on the solenoid. Put the other lead to a good

Alternator: Pulley Nut Tightening (Delco-Remy)

ground. No voltmeter reading shows there is a broken

circuit from the battery. Further testing is necessary

when there is a reading on the voltmeter.

Further test by fastening one voltmeter lead to the

connection (terminal) for the small wire at the solenoid

and the other lead to the ground. Look at the voltmeter

and activate the starter solenoid. A voltmeter reading

shows that the problem is in the solenoid. No voltmeter

reading shows that the problem is in the starter switch or

wiring. Fasten one lead of the voltmeter to the battery

wire connection of the starter switch and put the other

lead to a good ground. A voltmeter reading indicates a

failure in the switch.

A starting motor that operates too slow can have an

overload because of too much friction in the engine

ALTERNATOR PULLEY INSTALLATION

being started. Slow operation of the starting motor can

also be caused by shorts, loose connections, and/or dirt

1. 8S1588 Adapter (1/2" female to 3/8" male). 2. 8S1590

in the motor.

Socket (5/16"-3/8" drive). 3. 1P2977 Tool Group. 8H8555

Socket (15/16"-1/2" drive) not shown.

Pinion Clearance Adjustment (Delco-Remy)

Tighten nut holding the pulley to a torque of 60 5

Whenever the solenoid is installed, make an

lb. ft. (8.3 0.7 mkg) with the tools shown.

adjustment of the pinion clearance. The adjustment can

be made with the starting motor removed.

STARTING SYSTEM

Tools

Needed:

5P300

Electrical

Tester.