Cleaning , Inspection and Testing

TOOLS REQUIRED
^ J 544-01 Tension Scale
^ J 8001 Dial Indicator
^ J 26900-13 Magnetic Base
^ J 26900-5 Vernier Caliper
^ J 39200 Digital Multimeter

NOTE: Do not use grease dissolving solvents for cleaning the overrunning clutch or armature. Solvents dissolve the grease packed in the clutch and damage the armature and the field coil insulation.




1. Clean all starter motor parts.
2. Remove dirt and burn marks from the commutator end (2) of the armature (1) by sanding with a #300 or #400 grit sandpaper. Wipe the parts with a clean shop cloth.




3. Place the armature onto a pair of V-blocks (1). Measure the commutator run-out using the J 8001 with the J 26900-13. If the run-out exceeds the maximum, replace the armature.

Standard Commutator Run-out
0.05 mm (0.002 in) or less

Maximum Commutator Run-out
0.40 mm (0.016 in)




4. Measure the outside diameter of the commutator (2) using the J 26900-5. If the diameter is less than the minimum, replace the armature.

Standard Commutator Diameter
29.4 mm (1.16 in)

Minimum Commutator Diameter
28.8 mm (1.13 in)




5. Measure the depth of the commutator insulation. If the insulation depth is less than the minimum, replace the armature.

Standard Commutator Insulation Depth
0.4-0.6 mm (0.015-0.023 in)

Minimum Commutator Insulation Depth
0.2 mm (0.008 in)




6. Measure the resistance between the armature core (1) and the commutator (2) using J 39200. If the resistance is 5.0 ohms or less, the armature is grounded. Replace the armature.




7. Measure the resistance between the commutator segments using J 39200. If resistance is greater than 5.0 ohms at any test point, an open circuit exists in the commutator. Replace the armature.
8. Measure the resistance between the field coil and the field frame using the J 39200. If the resistance is 5 ohms or less, the field windings are grounded. Replace the field frame.




9. Measure the brush length using J 26900-5. If the brush length is less than the minimum, replace the brushholder.

Standard Brush Length
12.3 mm (0.44 in)

Minimum Brush Length
7 mm (0.28 in)




10. Inspect the brush holder and the insulation on the positive plates for wear. Replace the components as needed.
11. Measure the resistance between the positive brush holder and the negative brush holder using J 39200. If the resistance is 5.0 ohms or less, the brush holder is grounded. Replace the brush holder.




12. Inspect the brush springs for corrosion or damage.
13. Measure the brush spring (2) tension using J 544-01. If the tension is less than the minimum, replace the brush spring.

Standard Brush Spring Tension
1.9 kg (4.19 lbs)

Minimum Brush Spring Tension
0.7 kg (1.54 lbs)




14. Measure the starter solenoid pull-in coil resistance between terminal S (2) and terminal M using the J 39200. If the resistance is greater than 5.0 ohms, the pull-in coil is open. Replace the starter solenoid.




15. Measure the starter solenoid hold-in coil resistance between terminal S (3) and the solenoid case (1) using the J 39200. If the resistance is greater than 5.0 ohms, the hold-in coil is open. Replace the starter solenoid.




16. Inspect the pinion drive lever (4) for wear. Replace as necessary.




17. Inspect the overrunning clutch (1) for wear, damage or other abnormal conditions. Verify that the clutch locks when turned in the drive direction, and rotates smoothly in the reverse direction. Replace as necessary.




18. Inspect the overrunning clutch spine teeth (1) for wear or damage. Replace as necessary.




19. Inspect the armature bushing (1) for wear and damage. Replace as necessary.
20. Inspect the commutator end bushing for wear and damage. Replace as necessary.




21. Inspect the starter solenoid plunger operation by first pressing in the plunger and then releasing the plunger. If the plunger does not return to its original position quickly, replace the starter solenoid (1).




22. Inspect the internal gear assembly (1) and idle gears (2,3) for wear, damage or other abnormal conditions. Replace as necessary.