Inspection (Disassembly and Assembly)

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.