SkyTrak 6036 Service Manual - Manual (Page 213)

Section 10. Electrical System
Model 6036 S/N 9B0499 and Before 10-19
b. Disassembly of Starting Motor Relay
IMPORTANT: Do not disassemble starting motor
relay; service only as a complete assembly.
c. Cleaning and Drying
Without submerging the starting motor relay, clean
the relay using an approved solvent and dry with a
clean cloth.
d. Inspection and Replacement
1. Test the operation of the relay by connecting a
12 Vdc positive source to terminal “S” and the
negative lead to the mounting bracket; replace
the relay if you don’t hear the contacts close.
2. Inspect the general condition of the casing and
terminals and replace the relay if damaged.
e. Installation
1. If it was removed, position the relay mounting
plate (17, Fig. 10.22) on the engine and
secure it with two capscrews (15) and two lock
washers (16). Use Loctite
® 222 on the
capscrews.
2. Install capscrew (13) through flat washer (12)
and the LEFT hole in the relay bracket. Place
a tooth-type lock washer (11) over the end of
the capscrew. Insert end of screw through
relay mounting plate (17) and secure the
screw with a flat washer (12) and a lock nut
(10). Repeat this installation through the right
hole in the relay bracket but without using a
tooth type lock washer between the relay
bracket and the relay mounting plate.
4. Install connector “S” from neutral start switch
terminal (9) by installing lock washer (8) and
hex nut (7).
5. Connect starting motor feed cable (6) by
installing lock washer (2) and hex nut (1).
6. Connect positive (+) battery cable (3) by
installing lock washer (5) and hex nut (4).
Fig. 10.23 Ignition Key Switch
4. Connect the positive (+) cable (2) to the
positive terminals on the batteries.
5. Connect the negative (–) cable (1) to the
negative terminals on the batteries.
6. Connect the ground cable (1) to the starter.
10.5.4 Starting Motor Relay
The starting motor relay, Fig. 10.22, consists of a
movable contact with a fixed coil in a weatherproof
casing.
The relay is internally grounded and is equipped
with two large and two small terminals. The small
terminal “S” is for connection to the ignition system
resistance wire. The two large terminals are for
connection between the batteries and the starting
motor.
Turning the ignition switch, with the transmission
in neutral, allows current to flow through the relay
coil via terminal “S” to the ground point on the
casing. The flow of current energizes the coil
forming a magnetic field which attracts a movable
contact. When the contacts fully close, current
from the batteries is allowed to flow to the starting
motor through the relay.
Once the key switch is released, the flow of
current to the coil is stopped thereby breaking the
magnetic field and allowing the return spring to
open the contacts. This action stops the current
flow from the batteries to the starting motor.
a. Removal of Starting Motor Relay and Relay
Mounting Plate
1. Disconnect negative (–) cable (2, Fig. 10.38)
from the batteries.
2. Disconnect positive (+) battery cable (3, Fig.
10.22) by removing hex nut (4) and lock
washer (5).
3. Disconnect starting motor feed cable (6) by
removing hex nut (1) and lock washer (2).
4. Disconnect neutral start switch connector (9)
from terminal “S” from by removing hex nut (7)
and lock washer (8).
5. Remove starting motor relay (14) from relay
mounting plate (17) by removing two self-
locking hex nuts (10) and flat washers (12)
from behind plate. On the left side of the
starter motor relay, remove a tooth-type lock
washer (11) from between the plate and the
starter relay. Then remove capscrews (13).
6. If necessary, remove relay mounting plate (17)
by removing two capscrews (15) and two flat
washers (16).
OFF POSITION
RUN POSITION
THERMO START POSITION
THERMO START AND
START POSITION
MA1061