Overhaul
OVERHAULHINT: Use high-temperature grease to lubricate the bearings and gears when assembling the starter.
1. REMOVE STARTER YOKE ASSEMBLY
a. Remove the dust protector.
b. Remove the nut, and disconnect the lead wire from the magnetic switch terminal.
c. Remove the 2 bolts, and pull out the starter yoke (with armature)from the magnetic switch.
d. Remove the O-ring from the starter yoke.
2. REMOVE MAGNET STARTER SWITCH ASSEMBLY
a. Remove the 2 screws, and separate the starter switch and starter housing.
b. Remove the O-ring, starter clutch steel ball, return spring, idler gear and bearing.
c. Using a magnetic finger, remove the steel ball from the clutch shaft hole.
3. REMOVE END COVER
a. Remove the 2 screws and end cover.
4. REMOVE STARTER BRUSH HOLDER ASSEMBLY
a. Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the 4 brushes, and remove the brush holder.
5. REMOVE STARTER ARMATURE ASSEMBLY
6. INSPECT STARTER ARMATURE ASSEMBLY
a. Check the commutator surface for contamination and burns.
If the surface is dirty or burnt, correct it with sandpaper (#400) or a lathe.
b. Check that the commutator dose not have an open circuit.
1. Measure the resistance between the segments of the commutator.
Standard: Below 1 Ohm
If the result is not as specified, replace the armature assembly.
c. Check that the commutator is not grounded.
1. Measure the resistance between the commutator and armature coil core.
Standard: 10 kOhm or higher
If the result is not as specified, replace the armature assembly.
d. Check the commutator circle runout.
1. Place the armature on the V-blocks.
2. Using a dial gauge, measure the circle runout.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than the maximum, correct it with sandpaper (#400) or replace the armature assembly.
e. Using a vernier caliper, measure the commutator diameter.
If the diameter is less than the minimum, replace the armature assembly.
f. Measure the undercut depth of the commutator.
If the undercut depth is less than the minimum, correct it with a hacksaw blade.
g. Check that the bearings rotate smoothly.
OK: Rotates smoothly
If necessary, replace the armature assembly.
7. INSPECT STARTER YOKE ASSEMBLY
a. Check the field coil resistance.
1. Using an ohmmeter, measure the resistance between the lead wire and both brushes.
Standard: Below 1 Ohm
If the result is not as specified, replace the starter yoke assembly.
b. Inspect the shunt coil resistance.
1. Using an ohmmeter, measure the resistance between the shunt coil terminals.
Standard: 1.5 to 1.9 Ohm at 20°C (68°F)
If the result is not as specified, replace the starter yoke assembly.
8. INSPECT BRUSH
a. Using a vernier caliper, measure the length of the brushes.
If the length is less than the minimum, replace the brush holder assembly and starter yoke assembly.
9. INSPECT STARTER BRUSH HOLDER ASSEMBLY
a. Check the brush insulation.
1. Check the resistance between the positive (+) and negative (-) brush holders.
Standard: 10 kOhm or higher
If the result is not as specified, repair or replace the end frame assembly.
b. Using a pull scale, measure the brush spring load.
If the spring load is less than the minimum, replace the brush springs.
10. INSPECT STARTER CLUTCH SUB-ASSEMBLY
a. Check that the starter clutch can rotate clockwise, but cannot rotate counterclockwise.
If the starter clutch is does not operate as specified, replace it.
11. INSPECT MAGNET STARTER SWITCH ASSEMBLY
a. Check that the pull-in coil does not have an open circuit.
1. Using an ohmmeter, measure the resistance between terminals 50 and C.
Standard: Below 1 Ohm
If the result is not as specified, replace the magnetic switch assembly.
b. Check that the hold-in coil dose not have an open circuit.
1. Using an ohmmeter, measure the resistance between terminal 50 and the switch body.
Standard: Below 2 Ohm
If the result is not as specified, replace the magnetic switch assembly.
12. INSTALL STARTER ARMATURE ASSEMBLY
a. Apply grease to the armature bearings.
b. Insert the armature into the yoke.
13. INSTALL STARTER BRUSH HOLDER ASSEMBLY
a. Place the brush holder on the starter yoke.
b. Using a screwdriver, hold the brush spring back, and connect the brush into the brush holder. Connect all 4 brushes.
NOTE: Check that the positive lead wires are not grounded.
c. Install a new O-ring to the groove of the starter yoke.
d. Install the end cover to the starter yoke with the 2 screws.
Torque: 3.8 N.m (39 kgf.cm, 34 in.lbf)
14. INSTALL MAGNET STARTER SWITCH ASSEMBLY
a. Apply grease to the steel ball.
b. Insert the steel ball into the clutch shaft hole.
c. Apply grease to the return spring.
d. Insert the return spring into the magnetic switch hole.
e. Place a new O-ring (1), the starter clutch (2), idler gear(3), and bearing(4) on the starter housing.
f. Install the starter housing to the magnetic switch with the2 screws.
Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)
15. INSTALL STARTER YOKE ASSEMBLY
a. Install a new O-ring to the groove of the starter yoke.
b. Align the protrusion of the starter yoke with the groove of the magnetic switch, and install the starter yoke and armature.
c. Install the starter yoke and armature with the 2 bolts.
Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)
d. Connect the lead wire to terminal C with the nut.
Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)
e. Install a new dust protector.