Overhaul
OVERHAUL1. REMOVE STARTER MAGNETIC SWITCH ASSEMBLY
a. Remove the nut, then disconnect the lead wire.
b. Remove the 2 screws, then remove the starter magnetic switch.
c. Remove the return spring and plunger from the starter drive housing.
2. REMOVE STARTER COMMUTATOR END FRAME ASSEMBLY
a. Remove the 2 bolts, then remove the starter commutator end frame together with the starter yoke.
b. Remove the starter commutator end frame from the starter yoke.
c. Remove the starter armature plate from the starter yoke.
3. REMOVE STARTER ARMATURE ASSEMBLY
a. Using a thin-bladed screwdriver, remove the starter commutator end frame cover.
b. Using snap ring pliers, remove the snap ring.
c. Remove the plate washer and starter armature from the starter commutator end frame.
4. REMOVE STARTER PLANETARY GEAR
a. Remove the 3 planetary gears from the starter drive housing.
5. INSPECT STARTER MAGNETIC SWITCH ASSEMBLY
a. Check the plunger.
1. Push in the plunger, then check that it returns quickly to its original position.
If necessary, replace the starter magnetic switch.
b. Check the resistance.
1. Using an ohmmeter, measure the resistance between terminals 50 and C.
Standard: 1 Ohm or lower
If the result is not as specified, replace the starter magnetic switch.
2. Using an ohmmeter, measure the resistance between terminal 50 and the body.
Standard: 2 Ohms or lower
If the result is not as specified, replace the starter magnetic switch.
6. INSPECT STARTER ARMATURE ASSEMBLY
a. Check the resistance.
1. Using an ohmmeter, measure the resistance between the segments.
Standard: 1 Ohm or lower
If the result is not as specified, replace the starter armature.
2. Using an ohmmeter, measure the resistance between the segment and coil core.
Standard: 10 MOhms or higher
If the result is not as specified, replace the starter armature.
b. Check the commutator depth.
1. Using vernier calipers, measure the commutator depth.
Standard: 3.1 mm (0.122 in.)
Maximum: 3.8 mm (0.150 in.)
If the commutator depth is greater than maximum, replace the starter armature.
7. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY
a. Check the brush length.
1. Using vernier calipers, measure the brush length.
Standard: 9.0 mm (0.354 in.)
Minimum: 4.0 mm (0.158 in.)
If the brush length is less than minimum, replace the starter commutator end frame.
b. Check the resistance.
1. Using an ohmmeter, measure the resistance between the positive (+) and negative (-).
Standard: 10 MOhms or higher
If the result is not as specified, replace the starter commutator end frame.
8. INSPECT STARTER DRIVE HOUSING ASSEMBLY
a. Check the starter clutch.
1. Rotate the clutch pinion gear counterclockwise, then check that it turns freely. Try to rotate the clutch pinion gear clockwise, then check that it locks.
If necessary, replace the starter drive housing.
9. INSTALL STARTER PLANETARY GEAR
a. Apply grease to the planetary gears and pin parts of the planet shaft.
b. Install the 3 planetary gears into the pin of the planet shaft.
10. INSTALL STARTER ARMATURE ASSEMBLY
a. Apply grease to the plate washer, armature shaft and new snap ring.
b. Install the starter armature and plate washer into the starter commutator end frame.
c. Using snap ring pliers, install the snap ring.
d. Check the snap ring length.
1. Using vernier calipers, measure the snap ring length.
Maximum: 5.0 mm (0.197 in.)
If the snap ring length is greater than maximum, replace the snap ring.
e. Install the commutator end frame cover into the starter commutator end frame.
11. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
a. Align the rubber of the starter commutator end frame with the convex cutout of the starter yoke, then install the starter commutator end frame into the starter yoke.
b. Align the keyway of the starter armature plate with the key inside the starter yoke, then install the starter armature plate into the starter yoke.
c. Apply grease to the starter armature gear.
d. Align the key of the starter yoke with the keyway of the starter dive housing, then install starter commutator end frame together with the starter yoke into the starter drive housing.
e. Tighten the 2 bolts.
Torque: 6.0 N.m (60 kgf.cm, 53 in.lbf)
12. INSTALL STARTER MAGNETIC SWITCH ASSEMBLY
a. Apply grease to the plunger and hook.
b. Install the plunger and return spring into the starter drive housing.
c. Install the starter magnetic switch into the starter drive housing.
d. Tighten the 2 screws.
Torque: 7.5 N.m (75 kgf.cm, 66 in.lbf)
e. Connect the lead wire with the nut.
Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)