Starter Cleaning, Inspection and Testing

TOOLS REQUIRED
^ J 544-01 Tension Scale
^ J 8001 Dial Indicator
^ J 26900-13 Magnetic Base
^ J 26900-5 Vernier Caliper
^ J 39200 Digital Multimeter

NOTE: Do not use grease dissolving solvents for cleaning the overrunning clutch or armature. Solvents dissolve the grease packed in the clutch and damage the armature and the field coil insulation.

1. Clean all starter motor parts.
2. Remove dirt and burn marks from the commutator end (2) of the armature (1) by sanding with a #300 or #400 grit sandpaper. Wipe the parts with a clean shop cloth.




3. Place the armature onto a pair of V-blocks (1). Measure the commutator run-out using the J8001 with the J26900-13. Replace the armature if the run-out exceeds the maximum.

Standard Commutator Run-out
0.05 mm (0.002 in)

Maximum Commutator Run-out
0.40 mm (0.016 in)




4. Measure the outside diameter of the commutator (2) using the J 26900-5. Replace the armature if the diameter of the commutator is less than the minimum.

Automatic transaxle - Standard Commutator Outside Diameter
29.4 mm (1.157 in)

Automatic transaxle - Minimum Commutator Outside Diameter
28.8 mm (1.134 in)

Manual transaxle - Standard Commutator Outside Diameter
32.0 mm (1.260 in)

Manual transaxle - Minimum Commutator Outside Diameter
31.4 mm (1.236 in)




5. Measure the commutator insulation depth (2).

Automatic Transaxle - Standard Insulation Depth
0.5-0.8 mm (0.020-0.031 in)

Manual Transaxle - Standard Insulation Depth
0.4-0.6 mm (0.016-0.024 in)

6. If the insulation depth is less than 0.2 mm (0.008 in), replace the armature.




7. Measure the resistance between the armature core (1) and the commutator (2) using J 39200. If the resistance is 5.0 ohms or less, the armature is grounded. Replace the armature.




8. Measure the resistance between the commutator segments using J 39200. If resistance is greater than 5.0 ohms at any test point, an open circuit exists in the commutator. Replace the armature.




9. With a manual transaxle, measure the resistance between the field coil lead wire and the yoke using J 39200. If the resistance is 5 ohms or less, the field windings are grounded. Replace the yoke.




10. Measure the brush length (1) using the J 26900-5. If the brush length is less than the minimum, replace the brush.

Automatic Transaxle Standard Brush Length
17.5 mm (0.69 in)

Automatic Transaxle Minimum Brush Length
12.0 mm (0.47 in)

Manual Transaxle - Standard Brush Length
17.0 mm (0.67 in)

Manual Transaxle Minimum Brush Length
11.5 mm (0.45 in)




11. Measure the resistance between the positive brush holder and the negative brush holder using J 39200. If the resistance is 5.0 ohms or less, the brush holder is grounded. Replace the brush holder.




12. Measure the brush spring tension using the J544-01. If the tension is less than the minimum, replace the spring.

Automatic Transaxle Standard Tension
2.1 kg (4.63 lbs)

Automatic Transaxle - Minimum Tension
0.7 kg (1.54 lbs)

Manual Transaxle - Standard Tension
1.6 kg (3.53 lbs)

Manual Transaxle - Minimum Tension
1.0 kg (2.20 lbs)




13. Measure the starter solenoid (1) pull-in coil resistance between terminal S (2) and terminal M using J 39200. If the resistance is greater than 5.0 ohms, the pull-in coil is open. Replace the starter solenoid.




14. Measure the starter solenoid (1) hold-in coil resistance between terminal S (3) and the solenoid case (1) using J 39200. If the resistance is greater than 5.0 ohms, the hold-in coil is open. Replace the starter solenoid.




15. Inspect the pinion drive lever (4) for wear. Replace as necessary.




16. Inspect the overrunning clutch (1) for wear, damage or other abnormal conditions. Verify that the clutch locks when turned in the drive direction, and rotates smoothly in the reverse direction. Replace as necessary.




17. Inspect the overrunning clutch spine teeth (1) for wear or damage. Replace as necessary.




18. Inspect the armature bushing for wear and damage. Replace as necessary.
19. With automatic Transaxles, inspect the armature bearing (1) for wear and damage. Replace as necessary.
20. With manual transaxles, inspect the commutator end bushing for wear and damage. Replace as necessary.




21. Inspect the starter solenoid plunger operation by first pressing in the plunger and then releasing the plunger. It the plunger does not return to its original position quickly, replace the starter solenoid (1).




22. Inspect the internal gear assembly (1) and idle gears (2,3) for wear, damage or other abnormal conditions. Replace as necessary.
23. Inspect the brush springs for corrosion or damage. Also inspect the brush holder and the insulation on the positive plates for wear. Replace the components as needed.