Disassembly and Assembly

STARTER MOTOR ASSEMBLY

DISASSEMBLY AND ASSEMBLY

Disassembly Steps 1-20:

DISASSEMBLY SERVICE POINTS

[A] MAGNETIC SWITCH REMOVAL

CAUTION

Do not clamp the yoke assembly with a vise.

Disconnect the lead from the M terminal of the magnetic switch.

[B] SNAP RING / STOP RING REMOVAL





1. Apply a long socket wrench of an appropriate size to the stop ring and strike the wrench to drive out the stop ring toward the pinion gear side.





2. Remove the snap ring with snap ring pliers, then remove the stop ring and overrunning clutch.

STARTER MOTOR PARTS CLEANING
1. Never clean in a solvent such starter motor parts as the magnetic switch, brush holder, and armature. If they are soaked in a solvent, their insulation could be impaired. When these parts require cleaning, wipe off contamination with cloth.
2. Never soak the drive unit in a solvent. If it is washed in a solvent, the grease having been packed in the overrunning clutch at the factory will be washed out. Wipe the drive unit with cloth if it requires cleaning.

REASSEMBLY SERVICE POINTS

]A[ STOP RING / SNAP RING INSTALLATION





Use a suitable puller to pull the stop ring until it gets 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: 0.10 mm (0.004 inch)





2. Check the outer diameter of the commutator.

Standard value: 29.4 mm (1.16 inch)
Minimum limit: 28.8 mm (1.13 inch)





3. Check the depth of the undercut between segments.

Standard value: 0.5 mm (0.02 inch)
Minimum limit: 0.2 mm (0.01 inch)

BRUSH HOLDER





Push the brush into the brush holder to make sure that the spring is working on the brush.
If the spring is not working, replace the brush holder.

OVERRUNNING CLUTCH





1. Make sure that the pinion cannot be turned counterclockwise, and can be turned clockwise freely.
2. Check the pinion for abnormal wear and damage.

BRUSHES





1. Check the commutator contacting surface of each brush for abnormal roughness. Also check the height of the brush. Replace the brush holder if the height is lower than the limit.

Limit: 7.0 mm (0.27 in)

2. When the contact surface of the brush is rectified or the brush holder is replaced, recondition the contact surface with sandpaper wrapped around the commutator.

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 the armature while slowly rotating 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.