98-1504

INSTALLATION INSTRUCTIONS
Tilton Super Starter - 54-4XXXX Series
DESCRIPTION
Tilton Engineering’s Super Starter® is designed to fit much like the OEM starter whenever possible. It’s compact size will often provide significantly more clearance for various
engine and chassis components. Many of the top manufacturers of oil pans, exhaust systems, and engine accessories have designed their products for use with the Super Starter®. Unfortunately, with the wide variety of components currently on the market, it is notpossible to guarantee that the installation of a starter will be a simple “bolt-on” for every
application. From time to time, a customer will have to perform minor modifications tothe engine block, oil pan, or even the starter mounting nose (only when recommendedby Tilton) to achieve the recommended clearance. Any modifications undertaken to install the Tilton Super Starter® are well worth the time and effort, as they will be rewarded
with the superior performance of the original high-torque mini-starter.
Rectangular Shim

INSTALLATIONIn all models of the Super Starter®, the relationship between the starter pinion and thering gear is important for proper operation. Due to the starter’s high operating torque,failure to install correctly will usually result in starter and/or ring gear damage. Be sure
to check the following items before attempting to use your Super Starter®. For proper
operation, the starter pinion-to-ring-gear must be .100” (± .040”) when pinion is in its
relaxed position (See Figure 2). Check this at several flywheel locations by manually rotating the flywheel to be sure that the ring gear is running true. If the pinion is too close,

Housing Shaped Shim

Round Shim

Figure 1

use the housing shaped shim and round shim (See Figure 1) included with the starter, tomove the pinion .062” away from the ring gear. If it is impossible to see the pinion when
the starter is installed (as with some cars with bellhousing-mounted starters), measurein from the face of the bellhousing that the starter rests against to the ring gear. Thenmeasure from the face of the starter nose to the end of the relaxed pinion. The difference
between the two measurements is the pinion-to-ring-gear clearance. When the pinion
is engaged into the ring gear, there needs to be .010”-.030” backlash between them (SeeFigure 3). This can be checked with a wire gauge when holding the pinion engaged into
the ring gear. (A small pry bar or flat-blade screwdriver can be used to help hold thepinion out.) If the fit is too tight on an engine-block-mounted starter, use the rectangularshim (See Figure 1) between the starter nose and engine block.
*Note: For block mounted starter applications, additional rectangular shims, if required, canFigure 2(Pinion Ring Gear Clea rance)

be purchased at most local auto parts stores.
If the starter solenoid interferes with the engine block or any component, determine if
the nose on the starter is an indexable model (most are). If so, the entire starter can berotated about the nose to gain additional clearance. Care must be taken that the starter
motor does not interfere with some of the kickout configurations of aftermarket oil pans.
*Maximize the clearance between the solenoid and heat sources like exhaust headers toprevent heat soak. Use of heat insulation wrap or a heat shield may be needed.

Figure 3(Ring gear backlash)SOLENOID CONFIGURATIONS

Figure 4(Standard Connection)

Standard (General Motors) Figure 4Connect the positive battery lead to the unused post on thesolenoid. Connect the smaller switch lead to the spade terminalon the solenoid.

Starter
SwitchBattery

Remote Solenoid Connection (Ford Or Chrysler) Figure 5

Figure 5(Remote Solenoid Connection)

If your vehicle has a remote solenoid, connect the large positive leadfrom the remote solenoid to the unused post on the starter solenoid.

SwitchJumper
Wire

Use the short jumper wire (provided) to connect the spade terminal
to the same starter solenoid post as shown.

Solenoid

Battery
Ignition Resistor Bypass Figure 6
If your vehicle requires an ignition resistor bypass, you can connect
the existing bypass wire to the lower stud IF a 10 amp. diode is placed

10 Amp Diode

Distributor

Figure 6(Ignition Resistor Bypas s)in the wire to prevent feedback voltage from reaching the starter.
Note: Resistor bypass was used only on some GM models (late-60’s,early-70’s) and applies to cars still using the OEM distributor and point-Switch

type ignition. If you are running an aftermarket distributor, you will notconnect the extra wire (usually purple) to anything

BatteryMinimum Sizes For Battery and Wiring• Battery CCA’s double the cubic inch displacement of the engine (Example: 350 CID = 700 CCA minimum)• 1/0 AWG copper wire for positive and negative cables• 10 AWG copper wire for starter switch (Switch rating of at least 30 amps)• Engine and chassis grounded (Both of equal size)*Following these guidelines will eliminate many common issues and allow the starter to perform as designed.
• Note: Battery voltage, either standard 12 volt or racing 16 volt , should always be checked when installing a new starter. Voltage measured
at the starter should be within 1 volt of the measured voltage at the battery. *If the voltage drop is more then 1 volt, all wiring should bechecked for proper size, and grounds checked for good connection.
• Voltage during cranking should not be less than 10 volts. If voltage is below 10 volts, verify wire size and that contact surfaces are cleanof any paint, powdercoating, corrosion. Verify battery condition with a load tester. Checking battery condition before every event should
become routine.
• Note: Vehicles with long wire runs from remote mounted batteries may need larger gauge wire. Keep in mind that every connection (terminal, switch, splice or union) is a likely place for current drop or loss. Connections should be solidy crimped or soldered, and sealed fromthe elements to prevent corrosion. All connections should be secure to resist loosening from vibration. Keeping wires away from high heatareas wherever possible and using high temperature reflective wrap where needed is recommended.

Tilton Engineering, Inc. 25 Easy Street • PO Box 1787 • Buellton, CA 93427 • www.tiltonracing.com