Overhaul
STARTER MOTOR ASSEMBLYDisassembly Steps 1-20:
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY SERVICE POINTS
<> SNAP RING AND STOP RING REMOVAL
1. Press a long socket wrench of appropriate size to the stop ring. Then tap the socket wrench to remove the stop ring to the pinion gear side.
2. After removing the snap ring (by using snap-ring pliers), remove the stop ring and the overrunning clutch.
STARTER MOTOR PART CLEANING
1. Do not immerse parts in cleaning solvent. Immersing the yoke and field coil assembly and/or armature will damage insulation. Wipe these parts with a shop towel only.
2. Do not immerse the drive unit in cleaning solvent. Overrunning clutch is pre-lubricated at the factory and solvent will wash lubrication from the clutch.
3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a shop towel.
ASSEMBLY SERVICE POINT
>>A<< STOP RING AND SNAP RING INSTALLATION
Using a suitable pulling tool, pull the overrunning clutch stop ring over the snap ring.
INSPECTION
COMMUTATOR CHECK
1. Place the armature on a pair of V-blocks, and check the deflection by using a dial gauge.
Standard value: 0.05 mm (0.002 inch)
Limit: 0.1 mm (0.004 inch)
2. Check the outer diameter of the commutator.
Standard value: 29.4 mm (1.16 inches)
Minimum limit: 28.8 mm (1.13 inches)
3. Check the depth of the undercut between segments.
Standard value: 0.5 mm (0.02 inch)
Minimum limit: 0.2 mm (0.008 inch)
BRUSH CHECK
1. Check the brush for roughness of the surface that contacts the commutator and check the brush length. Replace the brush holder if this measurement exceeds the limit.
Minimum limit: 7.0 mm (0.28 inch)
2. If the contacting surface has been corrected or the brush has been replaced, correct the contacting surface by winding sandpaper around the commutator.
OVERRUNNING CLUTCH CHECK
1. While holding the clutch housing, rotate the pinion. The drive pinion should rotate smoothly in one direction, but should not rotate in the opposite direction. If the clutch does not function properly, replace the overrunning clutch assembly.
2. Inspect the pinion for wear or burrs. If the pinion is worn or burred, replace the overrunning clutch assembly. If the pinion is damaged, also inspect the ring gear for wear or burrs.
FRONT AND REAR BRACKET BUSHING CHECK
Inspect the bushing for wear or burrs. If the bushing is worn or burred, replace the front bracket assembly or rear bracket assembly.
ARMATURE CHECK
1. Check that the armature coil is not grounded.
2. Place the armature in a growler.
3. Hold a thin steel blade parallel and just above while rotating the armature slowly in the growler. A shorted armature will cause a blade to vibrate and be attracted to the core. Replace the shorted armature.
4. Check the insulation between the armature coil cores and the commutator segments. They are normal if there is no continuity.
5. Check for continuity between the segments. The condition is normal if there is continuity.