Pinion Clearance Check

CAUTION: Refer to "CAUTIONS".

CAUTION: Keep fingers and tools away from opening in Drive End (DE) housing while making electrical connections. The strong shifting action of the solenoid could cause personal injury or damage as the drive pinion moves into cranking position.

1. Secure stating motor in vise or equivalent fixture so that the opening in the Drive End (DE) housing is accessible for measurement.
^ With power supply circuit open, make electrical connections.
^ The battery negative lead must be connected to a clean metal ground on the starter motor housing.
^ Assure that the field lead is disconnected and insulated from the solenoid field terminal.
2. Turn the power supply to the solenoid "S" terminal "ON". This energizes hold-in coil.
3. Momentarily ground solenoid field terminal to motor housing. This energizes the pull-in coil in the solenoid and causes drive pinion to move into cranking position.
4. Remove ground from the solenoid field terminal. The drive pinion will stay in the cranking position when the ground is removed.
5. Press on drive just enough to take up any free movement of the pinion on the shaft. Use feeler gages to check clearance between end of pinion and pinion stop collar.
Measure
^ clearance should be 0.25 to 4.06 mm (0.010 to 0.160 in.).
6. After measuring the pinion clearance, turn the power supply switch "OFF".
7. If the clearance is outside specifications:
^ SD205 Starter Motor: Recheck the starter motor for worn or damaged parts in the shift mechanism and drive. Replace any worn or damaged parts.
^ PG260F and PG260M Starter Motor: Replace the starter motor.
8. If the pinion clearance is within specifications, reconnect the field lead to the starter solenoid as described in "Starter Assembly".