Inspection Procedure

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 burn marks and dirt from the commutator end (2) of the armature (1) by sanding with a #300 or with a #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 J 8001 with the J 26900-13. 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.

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

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

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

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




5. Measure the commutator insulation depth (2).

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

Standard Insulation Depth - Manual Transaxle
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.

Standard Brush Length - Automatic Transaxle
17.5 mm (0.69 in)

Minimum Brush Length - Automatic Transaxle
12.0 mm (0.47 in)

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

Minimum Brush Length - Manual Transaxle
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.

Standard Tension - Automatic Transaxle
2.1 kg (4.63 lb)

Minimum Tension - Automatic Transaxle
0.7 kg (1.54 lb)

Standard Tension - Manual Transaxle
1.6 kg (3.53 lb)

Minimum Tension - Manual Transaxle
1.0 kg (2.20 lb)




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




14. Measure resistance of the hold-in coil of the starter solenoid (1) between terminal S (3) and the solenoid case (1) J 39200 using. 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 the pinion drive lever, as necessary.




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




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




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




21. Press and release the starter solenoid plunger in order to inspect the operation. If the plunger does not return quickly, replace the starter solenoid (1).




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