Starter Motor: Service and Repair
STARTER MOTOR ASSEMBLYREMOVAL AND INSTALLATION
Pre-removal & Post-installation Operation:
Removal Steps 1-3:
REMOVAL SERVICE POINT [[A]] STARTER CONNECTOR AND TERMINAL/STARTER ASSEMBLY REMOVAL
1. Slide the starter, and remove the starter connector and terminal.
2. Remove the starter assembly from the lower front of the engine.
INSPECTION
PINION GAP ADJUSTMENT
1. Disconnect the lead wire from the M-terminal of the magnetic switch.
2. Connect a 12-volt battery between the S-terminal and M-terminal.
CAUTION
This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
3. Set the switch to "ON", and the pinion will move out.
4. Check the pinion-to-stopper clearance (pinion gap) with a feeler gauge.
Standard value: 0.5-2.0 mm (0.02-0.07 inch)
5. If the pinion gap is out of specification, adjust by adding or removing gasket(s) between the magnetic switch and front bracket.
MAGNETIC SWITCH PULL-IN TEST
1. Disconnect the field coil wire from the M-terminal of the magnetic switch.
CAUTION
This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal and M-terminal.
3. If the pinion moves out, the pull-in coil is good. If it doesn't, replace the magnetic switch.
MAGNETIC SWITCH HOLD-IN TEST
1. Disconnect the field coil wire from the M-terminal of the magnetic switch.
CAUTION
This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal and body.
3. Manually pull out the pinion as far as the pinion stopper position.
4. If the pinion remains out, everything is operating properly. If the pinion moves in, the hold-in circuit is open. Replace the magnetic switch.
FREE RUNNING TEST
1. Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to the starter motor as follows:
2. Connect a test ammeter (100-ampere scale) and carbon pile rheostat in series between the positive battery terminal and starter motor terminal.
3. Connect a voltmeter (15-volt scale) across the starter motor.
4. Rotate carbon pile to full-resistance position.
5. Connect the battery cable from the negative battery terminal to the starter motor body.
6. Adjust the rheostat until the battery positive voltage shown by the voltmeter is 11 V.
7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely.
Current: maximum 90 Amps
MAGNETIC SWITCH RETURN TEST
1. Disconnect the field coil wire from the M-terminal of the magnetic switch.
CAUTION
This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the M-terminal and body.
WARNING
Be careful not to get your fingers caught when pulling out the pinion.
3. Pull the pinion out and release. If the pinion quickly returns to its original position, everything is operating properly. If it doesn't, replace the magnetic switch.
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: 0.1 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 (0.008 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.