Cleaning, Inspection and Testing

TOOLS REQUIRED:
J 54401 Steering wheel Tension Scale
J 8001 Dial Indicator
J 26900-13 Magnetic Base
J 26900-5 Vernier Caliper
J 34029-A Digital Multimeter
CLEAN
^ All starter motor parts.

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

Cleaning Commutator:

^ Remove dirt and burns from the commutator by sanding with a #300 or #400 grit sandpaper. Wipe parts with a clean shop cloth.

MEASURE

Measuring Commutator Run-Out:

1. Place the armature onto a pair of "V-blocks." Using a J 8001 with a J 26900-13, measure commutator run-out. Standard commutator run-out is 0.05 mm (0.002 inch). If run-out exceeds 0.40 mm (0.016 inch) replace the armature.

Measuring Commutator Wear:

2. Commutator wear using a J 26900-5 to measure the outside diameter of the commutator. Standard commutator outside diameter is 32.0 mm (1.260 inch) (manual transaxle equipped vehicles) or 29.4 mm (1.157 inch) (automatic transaxle equipped vehicles). If the outside diameter is less than 31.4 mm (1.236 inch) (manual transaxle equipped vehicles) or 28.8 mm (1.134 inch) (automatic transaxle equipped vehicles), replace the armature.

Measuring Commutator Insulation Depth:

3. Commutator insulation depth. Standard commutator insulation depth is 0.4 to 0.6 mm (0.016 inch to 0.024 inch) (manual transaxle equipped vehicles) or 0.5 to 0.8 mm (0.020 inch to 0.031 inch) (automatic transaxle equipped vehicles). If insulation depth is less than 0.2 mm (0.008 inch), replace the armature.

Measuring Armature Core-to-Commutator Resistance:

4. Resistance between armature core and commutator using a J 34029-A. If resistance is 5 ohms or less, the armature is grounded and must be replaced.

Measuring Commutator Resistance:

5. Resistance between commutator segments using the J 34029-A. If resistance is not 5 ohms or less at any test point, there is an open circuit in the commutator and the armature must be replaced.

Measuring Yoke-to-Field Coil Lead Wire Resistance:

6. Resistance between the field coil lead wire and the yoke using the J 34029-A (manual transaxle equipped vehicles). If resistance is 5 ohms or less, the field windings are grounded and the yoke must be replaced.

Measuring Brush Length:

7. Brush length using the J 26900-5. Standard brush length is 17.0 mm (0.67 inch) (manual transaxle equipped vehicles) or 17.5 mm (0.69 inch) (automatic transaxle equipped vehicles). If brush length is less than 11.5 mm (0.45 inch) (manual transaxle equipped vehicles) or 12.0 mm (0.47 inch) (automatic transaxle equipped vehicles), replace the brush.

Measuring Brush Holder Resistance:

8. Resistance between positive brush holder and negative brush holder using the J 34029-A. If resistance is 5 ohms or less, the brush holder is grounded and must be replaced.

Measuring Brush Spring Tension:

9. Brush spring tension using a J 544-01. Standard tension is 1.6 kg (3.53 lbs.) (manual transaxle equipped vehicles) or 2.1 kg (4.63 lbs.) (automatic transaxle equipped vehicles). If brush spring tension is less than 1.0 kg (2.20 lbs.) (manual transaxle equipped vehicles) or 0.7 kg (1.54 lbs.) (automatic transaxle equipped vehicles), the brush spring must be replaced.

Measuring Solenoid Pull-In Coil Resistance:

10. Solenoid pull-in coil resistance between terminal "S" and terminal "M" using the J 34029-A. If resistance is not 5 ohms or less, the pull-in coil is open and the solenoid must be replaced.

Measuring Solenoid Hold-In Coil Resistance:

11. Solenoid hold-in coil resistance between terminal "S" and the solenoid case using the J 34029-A. If resistance is not 5 ohms or less, the hold-in coil is open and the solenoid must be replaced.
Inspect
1. Pinion drive lever for wear; replace if necessary.

Inspecting Overrunning Clutch Operation:

2. Overrunning clutch for wear, damage or other abnormal conditions. Check that the clutch locks when turned in the drive direction and rotates smoothly in the reverse direction. Replace if necessary.

Inspecting Overrunning Clutch Spline Teeth:

3. Overrunning clutch spline teeth for wear or damage; replace if necessary.
4. Commutator end bushing for wear or damage; replace if necessary (manual transaxle equipped vehicles).
5. Armature bushing for wear or damage; replace if necessary.
6. Armature bearing for wear or damage; replace if necessary (automatic transaxle equipped vehicles).

Inspecting Solenoid Plunger Operation:

7. Solenoid plunger operation by pressing the plunger in and releasing it. If the plunger does not return to its original position quickly, the solenoid must be replaced.
8. Internal gear assembly and idle gears for wear, damage or other abnormal conditions; replace if necessary (automatic transaxle equipped vehicles).